Factory Workshop Manual
Make
Ford
Model
Explorer Sport Trac 4wd
Engine and year
V8-4.6L VIN 8 (2007)
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This manual was submitted by
Anonymous
Date
1st January 2018
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 12
C3267
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 13
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 14
Explorer Sport Trac
Removal and Installation
Mountaineer
1. Remove the passenger rear quarter trim panel.
Explorer Sport Trac
2. Remove the cab rear trim panel.
All vehicles
3. Remove the bolt and the parking aid module.
- Disconnect the electrical connectors.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal
Positioning Module > Component Information > Description and Operation
Pedal Positioning Module: Description and Operation
Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver
can adjust the brake and accelerator pedals for a more comfortable driving position. For removal
and installation of the adjustable pedals, refer to Brake Pedal and Bracket.
Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational
with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward
using the adjustable pedal switch.
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Description and Operation
Memory Positioning Module: Description and Operation
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module >
Component Information > Description and Operation
Pedal Positioning Module: Description and Operation
Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver
can adjust the brake and accelerator pedals for a more comfortable driving position. For removal
and installation of the adjustable pedals, refer to Brake Pedal and Bracket.
Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational
with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward
using the adjustable pedal switch.
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Service and Repair
Auxiliary Step / Running Board Module: Service and Repair
RETRACTABLE RUNNING BOARD MODULE
Removal and Installation
1. Remove the RH C-pillar trim panel. 2. Disconnect the retractable running board module electrical
connectors. 3. Remove the 3 screws and the retractable running board module assembly.
- To install, tighten to 7 Nm (62 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 31
C921
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay >
Component Information > Locations > Page 35
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control
Module: > 06-6-9 > Apr > 06 > ABS/TCS/RCS - Warning Lamp ON/DTC C1440 Set
Electronic Brake Control Module: Customer Interest ABS/TCS/RCS - Warning Lamp ON/DTC
C1440 Set
TSB 06-6-9
04/03/06
ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL
INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Sport Trac vehicles built through
3/16/2006 may exhibit an anti-lock brake system / traction control / roll stability control (ABS / TC /
RSC light) warning lamp illuminated with diagnostic trouble code C1440 pressure transducer main /
primary signal faulted. This may be caused by the integrated control unit (ICU).
ACTION Follow the Service Procedure to determine if the ABS module needs to be replaced.
NOTE
THE BASE BRAKE SYSTEM CONTINUES TO FUNCTION PROPERLY.
SERVICE PROCEDURE
1. Install scan tool, retrieve DTCs and record.
a. If DTC C1440 is retrieved, proceed to Step 2.
b. If DTC C1440 is not retrieved, this TSB does not apply. Proceed with normal diagnostics.
2. Replace the ABS module (2C219). Refer to Workshop Manual, Section 206-09 for Removal and
Installation procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 06-6-9 > Apr > 06 > ABS/TCS/RCS - Warning Lamp ON/DTC C1440 Set
Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS/RCS - Warning Lamp
ON/DTC C1440 Set
TSB 06-6-9
04/03/06
ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL
INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Sport Trac vehicles built through
3/16/2006 may exhibit an anti-lock brake system / traction control / roll stability control (ABS / TC /
RSC light) warning lamp illuminated with diagnostic trouble code C1440 pressure transducer main /
primary signal faulted. This may be caused by the integrated control unit (ICU).
ACTION Follow the Service Procedure to determine if the ABS module needs to be replaced.
NOTE
THE BASE BRAKE SYSTEM CONTINUES TO FUNCTION PROPERLY.
SERVICE PROCEDURE
1. Install scan tool, retrieve DTCs and record.
a. If DTC C1440 is retrieved, proceed to Step 2.
b. If DTC C1440 is not retrieved, this TSB does not apply. Proceed with normal diagnostics.
2. Replace the ABS module (2C219). Refer to Workshop Manual, Section 206-09 for Removal and
Installation procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 50
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 51
C155
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 52
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Material
Removal and Installation
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
CAUTION: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and
calibrated. Follow the scan tool directions for the calibration procedures. For module configuration,
refer to Information Bus.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 53
1. Remove the hydraulic control unit (HCU).
2. CAUTION: Make sure that the ABS module is properly seated to the HCU and that the torque of
the ABS module screws is correct, or
damage to the components can occur.
Remove the 4 screws and the ABS module. ^
To install, tighten to 2 Nm (18 inch lbs.).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations > Page 57
C239
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay 1 > Page 63
View 151-10 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 64
C2017
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay 1 > Page 67
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 71
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR)
NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to
monitor the A/CCR output.
The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch
or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives
a signal indicating that A/C is requested. For some applications, this message is sent through the
communications network. When A/C is requested, the PCM checks other A/C related inputs that
are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C
operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle
position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to
the A/CCR.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 72
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Page 76
Control Module HVAC: Diagrams
C228A
C228B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 86
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module:
> 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module:
> 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 92
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 101
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip
Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 107
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
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Component Information > Locations
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Component Information > Locations > Page 120
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
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Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
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Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Fuse
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Fuse
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Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 138
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
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Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 139
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
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Fuse
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Fuse
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Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 143
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
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Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 144
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
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Component Information > Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
C1035A
C1035B
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 147
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 148
C2280B
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 149
C2280C
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 150
C2280D
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Component Information > Diagrams > Battery Junction Box (BJB) > Page 151
C2280E
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Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
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154
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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Fuse
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156
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157
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158
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
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Fuse
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Fuse
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Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
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Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Specifications
Torque Specifications
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat
Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
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Module (DSM) > Page 170
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration
information to a scan tool. This information must be downloaded into the new DSM after
installation.
1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors
and remove the DSM.
4. NOTE: Once the module is installed it is necessary to download the module configuration
information from the scan tool into the new module.
To install, reverse the removal procedure.
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Body Control Module: Service and Repair Smart Junction Box (Sjb)
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
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Module (DSM) > Page 172
Part 2
Removal
NOTE:
- The steps included in the SJB removal and installation procedure are critical to restoring the
vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered
in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure
monitoring system. The presence of these DTCs requires the installation procedures be followed in
order to clear the DTCs and enable normal SJB operations.
- Prior to the removal of the SJB, it is necessary to upload the module configuration information to
the diagnostic tool. This information must be downloaded to the new SJB after installation.
1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside.
3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for
the release lever to slide through the trim panel.
Remove the pushpin and the cowl side trim panel.
4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake
switch electrical connector. 6. Release the hood release cable pushpin from the parking brake
control bracket. 7. Release the harness clip from the parking brake cable housing.
8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the
instrument panel reinforcement.
Remove the 3 bolts and position the parking brake control assembly under the brake pedal.
9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the
instrument panel and may be broken if
any prying force is exerted in the lower area of the bezel.
Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the
instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside.
10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11.
Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the
instrument panel, remove the third SJB bolt.
13. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
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(connected) position when installing.
Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the
SJB.
Installation
NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program
the RKE transmitters to the new SJB.
1. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
(connected) position when installing.
Position the SJB into the 2 locating pins and connect the 5 electrical connectors.
2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel
opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5.
Connect the 2 electrical connectors and install the headlight switch bezel assembly into the
instrument panel. 6. Position the parking brake control assembly and install the 3 bolts.
- Tighten to 20 Nm (15 lb-ft).
7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable
pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical
connector.
10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release
lever assembly and install the bolt.
12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the
release lever to slide through the trim panel.
Position the cowl side trim panel and install the pushpin.
13. Position the LH door opening weather seal. 14. Install the driver door scuff plate.
15. NOTE: When successful, this step provides the calibration necessary for SJB operation and
clears DTC B2477. The clearing of the DTC
indicates the calibration data has been successfully downloaded to the SJB.
Download the SJB configuration information from the diagnostic tool to the SJB.
16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing
of these DTCs indicates the SJB has recognized
the tire pressure sensors during the training procedure.
Train the tire pressure sensors.
17. Clear the DTCs.
18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing
mode, and to be sure there are no other concerns with
the newly programmed SJB.
Carry out the SJB on-demand self-test.
19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters
do not need to be reprogrammed to the vehicle.
However, if the module configuration upload/download is unsuccessful and as-built data must be
used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed
to the vehicle.
Program the RKE transmitters to the new SJB (if necessary).
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and
Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The torque based ETC is a hardware and software strategy that delivers an engine output torque
(via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the
powertrain control module (PCM), and an accelerator pedal assembly to control the throttle
opening and engine torque. The ETC system replaces the standard cable operated accelerator
pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable camshaft
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: eliminate cruise control actuators
- eliminate idle air control (IAC) valve
- better airflow range
- packaging (no cable)
- more responsive powertrain at altitude and improved shift quality
It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on
the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble
codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC
motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position
signals are required for increased monitoring
reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and
the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal
operation the negative slope TP signal (TP1) is used by the control strategy as the indication of
throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage
- Signal return (ground)
- TP1 voltage with negative voltage slope (5-0 volts)
- TP2 voltage with positive voltage slope (0-5 volts)
Accelerator Pedal Position (APP) Sensors
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Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts)
- 2 signal return (ground) circuits
- APP1 voltage with negative voltage slope (5-0 volts)
- APP2 voltage with positive voltage slope (0-5 volts)
- APP3 voltage with positive voltage slope (0-5 volts)
3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
concern. The PCM determines if a signal is
incorrect by calculating where it should be, inferred from the other signals. A value is substituted for
an incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
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ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver
pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
ETC System Failure Mode And Effects Management (Part 1)
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Operation > Page 179
ETC System Failure Mode And Effects Management (Part 2)
Since the IPC and the main controller share the same processor, they are subject to a number of
potential common failure modes. The E-Quizzer processor was added to redundantly monitor
selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC
and the main processor. If it determines that the IPC function is impaired in any way, it takes
appropriate failure mode and effects management (FMEM) actions.
Electronic Throttle Monitor Operation:
Electronic Throttle Monitor Operation (Part 1)
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Operation > Page 180
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
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Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position.
- Greater than or equal to 4% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON,
engine OFF.
- Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential
ice buildup in the throttle body.
- Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard stop.
The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations
Engine Control Module: Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 185
View 151-8 (Engine, Rear - 4.6L)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions
Engine Control Module: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Symbols Part 2
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and Instructions > Page 193
Symbols Part 3
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and Instructions > Page 194
Symbols Part 4
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and Instructions > Page 195
Symbols Part 5
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Engine Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Engine Control Module: Connector Views
C175B (Part 1)
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C175B (Part 2)
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C175E (Part 1)
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C175E (Part 2)
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C175T (Part 1)
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C175T (Part 2)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain
Control Module (PCM)
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
Removal
All vehicles
1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys.
Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation procedure.
Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner.
All vehicles
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3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position
the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove
the bolts and the PCM.
Installation
All vehicles
1. Install the PCM and bolts.
- Tighten to 10 Nm (89 lb-in).
2. Connect the PCM electrical connectors.
3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front
wheel speed sensor electrical connector.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner.
All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps
of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system
(PATS). Carry out the Parameter Reset procedure.
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Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit (IC) internal to the powertrain control module
(PCM). The EEPROM contains the vehicle strategy including calibration information specific to the
vehicle, and is capable of being programmed or flashed repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan
tool manufacturer's instruction manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and needs programming. There are 2 procedures available. The first is an
automatic data transfer from the old PCM to the new PCM, and the second is manual data entry
into the new PCM.
Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by
using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored
data can then be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old module is damaged or incapable of communicating. Remove
and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter
programming, referring to the scan tool manufacturer's instruction manual. Make certain that all
parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile
equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF
may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center
for the information needed to manually update the VID block with the scan tool. Contact the center
only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury
technicians, contact your National Hotline or the Professional Technician Society (PTS) website for
As-Built data listed under the Service Publications Index. Non-Ford technicians use the
Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search
function to find the Module Programming or As-Built Data.
For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the
PTS website for quick Programmable Module data information by vehicle.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to Module Reprogramming on the scan tool.
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C1450
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View 151-27 (Rear End)
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C4033
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Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal and Installation
1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM)
electrical connector. 3. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Air Bag Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Air Bag Control Module: Locations
View 151-15 (Center Console)
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View 151-17 (Right Front)
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Air Bag Control Module: Diagrams
C310A
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C310B (Part 1)
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C310B (Part 2)
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Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed.
In addition, make sure the area of the RCM mounting is restored to its original condition.
CAUTION: When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry
out programmable module installation (PMI).
NOTE: When installing a new RCM, always make sure the correct RCM is being installed. If an
incorrect RCM is installed, erroneous DTCs will result.
The RCM carries out the following functions:
- deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioner and safety belt adaptive load limiting retractor to
control tension on the safety belt.
- monitors the SRS for faults.
- requests the illumination of the air bag indicator if a fault is detected.
- communicates through the DLC the on-demand or continuous DTCs.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the ON position, the RCM will request illumination of 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 6 seconds and then off. If a SRS fault exists, the air bag indicator will illuminate and
remain illuminated for the rest of the key cycle. The RCM will also communicate the on-demand
(current) and continuous (historical) DTCs through the DLC, to the scan tool. If the RCM requests
illumination of the air bag indicator and the air bag indicator does not function, the instrument
cluster module will automatically activate an audible chime. The chime is a series of 5 sets of 5
tone bursts. If the chime is heard, the SRS and the air bag indicator require repair.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is lost or damaged during impact. The backup
power supply will deplete its stored energy approximately one minute after the battery ground cable
is disconnected.
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Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
Special Tool(s)
Removal
WARNING:
- Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag
module. This will reduce the risk of injury in the event of an accidental deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be installed new whether or not the air bags have deployed. In addition, make sure the
area of
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Component Information > Technical Service Bulletins > Page 261
the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or
any other damaged SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag RCM retaining nuts is critical for correct system operation.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
can result.
- When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out
programmable module installation (PMI). See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning
NOTE:
- When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect
RCM is installed, erroneous DTCs will result.
- 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 SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
Vehicles built 7/31/06 or after 1. Carry out the steps necessary to prepare for programmable
module installation (PMI).
All vehicles 2. Depower the system. 3. Remove the floor console.
4. Disconnect the large restraints control module (RCM) electrical connector.
1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the
way back until it stops.
2 Pull out and disconnect the large RCM electrical connector.
5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove
the 3 RCM nuts. 7. Remove the RCM.
Installation
All vehicles 1. Install the RCM.
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2. Install the 3 RCM nuts.
- Tighten to 12 Nm (9 lb-ft).
3. Connect the small RCM electrical connector.
4. NOTE: The RCM has been removed for clarity.
On the large RCM electrical connector, place the connector position assurance lever in the full
release position.
5. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
Position the large RCM electrical connector into the RCM.
6. Connect the large RCM connector.
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- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
- Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
7. Install the floor console. 8. Repower the system. Do not prove out the SRS at this time.
Vehicles built 7/31/06 or after 9. Carry out the steps necessary to complete PMI.
All vehicles 10. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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269
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
270
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
271
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272
DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s)
or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the
specific device and fault condition. Fault PIDs are available for both on-demand (active) and
continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and
their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures
1-5)
VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs
The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools
have transitioned. Examples of how the WSM may direct you to view fault PIDs are:
^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms)
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Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
273
^ 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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274
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Description and Operation
Seat Occupant Classification Module - Air Bag: Description and Operation
OCS SYSTEM MODULE
Based on programmed limits, the OCS module will inform the RCM, via a High Speed Controller
Area Network (HS-CAN), of the necessary information. The RCM uses this information in
determining if the passenger air bag module or passenger seat side air bag module is to be
deployed in the event of a deployable collision.
The OCS module monitors the OCS system for faults and communicates on-demand and
continuous diagnostic trouble codes (DTCs) via the DLC with the use of a scan tool.
The components that make up the OCS system, OCS system module, inboard OCS rail and
outboard OCS rail are serviced separately.
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Module - Air Bag > Component Information > Description and Operation > Page 278
Seat Occupant Classification Module - Air Bag: Service and Repair
OCCUPANT CLASSIFICATION MODULE
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Power seat shown, manual similar.
- Seat is removed for clarity.
1. Depower the system. 2. From underneath the front of the seat, disconnect the OCS module
electrical connector.
3. NOTE: Note the position of the locator tab on the OCS module for installation.
Remove the 2 screws and the OCS module. To install, tighten to 2 Nm (18 lb-in).
4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this
time.
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6. Carry out the appropriate procedure after installation of an OCS system component.
- If installing the original OCS system component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. See: Restraint Systems/Air Bag
Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant
Classification Sensor (OCS) System Zero Seat Weight Test
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. See: Restraint Systems/Air Bag Systems/Service
and Repair
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay
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Component Information > Locations > Starter Relay > Page 285
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Component Information > Testing and Inspection > Run/Start Relay
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Component Information > Testing and Inspection > Run/Start Relay > Page 288
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module:
> 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: Customer Interest Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module:
> 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page 299
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module:
> 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module:
> 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 304
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module:
> 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 305
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module:
> 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 306
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: All Technical Service Bulletins Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page 312
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 317
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 318
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 319
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Locations
View 151-9 (Automatic Transmission)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 324
Control Module: Diagrams
C281A
C281B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 325
Control Module: Service and Repair
Four Wheel Drive (4WD) Control Module
Four Wheel Drive (4WD) Control Module
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Open the
glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4.
Disconnect the electrical connectors. 5. Remove the four wheel drive (4WD) control module. 6. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Rear Window Defrost Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations > Rear Window Defrost Relay > Page 331
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 334
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 339
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left
C4009
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 347
C4011
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 348
C4010
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 349
C4012
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Diagrams > Page 350
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
Removal and Installation
1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor(s) electrical connector(s).
3. Press the retaining tabs and remove the parking aid sensor(s). 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal
Positioning Switch > Component Information > Locations > Page 354
C2089
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door
Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Removal and Installation
1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3.
Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 360
Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Removal and Installation
1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch
counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 361
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Removal and Installation
1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch
counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 362
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Removal and Installation
1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and
remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 366
C2089
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Lock Switch, Passenger Side
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Lock Switch, Passenger Side > Page 371
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Door Lock Switch, Driver Side
C505
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Door Lock Switch, Driver Side > Page 374
C605
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 375
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 376
Power Door Lock Switch: Service and Repair
DOOR LOCK CONTROL SWITCH
Removal and Installation
NOTE: The LH side is shown, the RH side is similar.
1. Remove the interior door handle cover. 2. Remove the front door switch bezel.
- Release the 4 retaining tabs.
3. Disconnect the door lock control switch and window control switch electrical connectors. 4.
Remove the door lock control switch.
- Release the 4 retaining tabs.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 377
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 381
C527
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 382
Power Mirror Switch: Testing and Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 383
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 384
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
Removal and Installation
1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front
door trim panel. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Locations > Page 388
Power Seat Switch: Diagrams
C352
C3016
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 391
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Page 392
Power Seat Switch: Service and Repair
MEMORY SET SWITCH
Removal and Installation
1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center
console door, remove the 2 screws and pull up on the console finish panel to release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out
to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6.
Pull out to release the retainers and separate the instrument panel center finish panel. 7.
Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Belt Tower Position
Sensor > Component Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Locations > Page 399
C2347
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch
Seat Heater Switch: Service and Repair Heated Seat Switch
HEATED SEAT SWITCH
Removal and Installation
1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center
console door, remove the 2 screws and pull up on the console finish panel to release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out
to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6.
Pull out to release the retainers and separate the instrument panel center finish panel. 7.
Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated
windshield switch pack. 8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 402
Seat Heater Switch: Service and Repair Seat Control Switch
SEAT CONTROL SWITCH
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 403
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 404
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 405
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 406
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 407
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 408
Passenger Seat Cushion (Part 2)
Exploded View
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
cushion side shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 409
1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the
manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5.
From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side
shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap
from the cushion side shield. 8. Remove the seat control switch knob and separate the seat control
switch from the cushion side shield.
- Remove the cushion side shield.
3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5.
Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out
the SRS at this time.
Passenger seat
6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Heated Seat Switch > Page 410
Seat Heater Switch: Service and Repair Seat Control Switch - Third Row
SEAT CONTROL SWITCH - THIRD ROW
Removal and Installation
1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel. 2.
Disconnect the third row seat control switch(es), release the retainers and remove the third row
seat control switch(es). 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit
Switch > Component Information > Service and Repair
Sunroof / Moonroof Limit Switch: Service and Repair
ROOF OPENING PANEL CONTROL SWITCH
Removal and Installation
1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors.
3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Locations > Page 417
Sunroof / Moonroof Switch: Diagrams
C912
C9001
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations
View 151-15 (Center Console)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 422
C3073
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 423
ABS Sensor Block: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 424
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster
Vacuum Sensor > Component Information > Locations > Page 428
C149
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 432
C124
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair > Page 436
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Diagrams
C2015
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Steering Wheel Rotation Sensor
Removal and Installation
1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2.
Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor
electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install,
reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 446
C280
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 447
Traction Control Switch: Service and Repair
Stability/Traction Control Switch
Removal and Installation
1. Remove the 2 floor console center finish panel screws and the floor console center finish panel.
^ To install, tighten to 9 Nm (80 inch lbs.).
2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the
instrument panel center finish panel away from the instrument panel. 5. Disconnect the stability
traction control switch electrical connector and remove the stability traction control switch from the
instrument panel
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Locations > Page 448
center finish panel.
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 453
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front
C150
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 456
C440
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 457
C160
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 458
C426
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front
Wheel Speed Sensor - Front
Wheel Speed Sensor - Front
Removal and Installation
1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3.
Remove the wheel speed sensor harness bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 461
4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor
bolt.
^ To install, tighten to 17 Nm (13 ft. lbs.).
6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 462
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Disconnect the wheel speed sensor electrical connector. 3.
Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt
and the wheel speed sensor.
^ To install, tighten to 8 Nm (71 inch lbs.).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair > Page 466
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed
Sensor > Component Information > Description and Operation
Radiator Cooling Fan Speed Sensor: Description and Operation
FAN SPEED SENSOR (FSS)
Cooling Fan Clutch With (FSS)
The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a
waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a
relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch
speed increases, the sensor generates a signal with a higher frequency. The powertrain control
module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop
control of the cooling fan clutch.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
C1064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 478
C107
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 479
Engine Temperature Sensor: Description and Operation
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical CHT Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases., and the resistance
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.
The CHT sensor is installed in the 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 initiates a
fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern
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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 480
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations > Deactivator Switch > Page 486
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Deactivator Switch
C277
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Diagrams > Deactivator Switch > Page 489
C278
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 492
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS) Brake
Deactivator Switch
BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Description and Operation > Page 493
Brake Switch (Cruise Control): Service and Repair
SPEED CONTROL DEACTIVATOR SWITCH
Removal
CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the speed control deactivator switch. Do not install the speed control deactivator switch
without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the
brake pedal when removing or installing the speed control deactivator switch, as misadjustment or
damage to the switch may occur.
1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise
45 degrees and remove the speed control deactivator switch.
Installation
NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the
proper position. Do not pull up or push down on the pedal during installation. Initial installation of
the speed control deactivator switch allows for one adjustment. If additional adjustments are
necessary, install a new switch.
1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the
speed control deactivator switch electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
SPEED CONTROL SWITCH
Removal and Installation
NOTE:
- It is not necessary to remove the driver air bag module during this procedure.
- Be careful not to allow the speed control switch electrical connector to fall back into the steering
wheel.
1. Remove the speed control switch by pulling the switch toward the rear of the vehicle.
- Disconnect the electrical connector.
2. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations > Page 504
C103
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch,
Engine > Component Information > Description and Operation
Oil Temperature Sensor/Switch: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical EOT Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance changes 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 sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control
gains and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM begins reducing power by disabling engine cylinders.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component
Information > Locations
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component
Information > Locations > Page 512
C2208
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 516
C132
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 517
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
Removal and Installation
Mountaineer
1. Remove the radiator grille.
2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air
deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator
support.
All vehicles
4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air
temperature sensor. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations
View 151-11 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 521
C271
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Page 522
Blower Motor Switch: Service and Repair
BLOWER MOTOR SPEED CONTROL
Removal and Installation
1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3.
Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 526
C233
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 527
Cabin Temperature Sensor / Switch: Service and Repair
IN-VEHICLE TEMPERATURE SENSOR
Removal and Installation
1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance
The ACET sensor measures the 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 the resistance 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 changes 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, improve defrost/demist
performance, and reduce A/C clutch cycling.
NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were
calculated for VREF equals 5.0 volts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 535
C1078
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 539
C286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 544
C2298
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 545
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 546
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Locations > Page 547
3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 552
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 553
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 554
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front
C526
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 557
C602
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 558
C715
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 559
C820
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation
Fuel Gauge Sender: Description and Operation
FUEL PUMP (FP) MODULE
Typical Electronic Returnless Fuel Pump (FP) Module
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 563
Typical Mechanical Returnless Fuel Pump (FP) Module
The FP module 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.
FUEL PUMP (FP) MODULE AND RESERVOIR
The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check
valve that maintains the system pressure after the key has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 564
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 565
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 566
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 567
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 568
All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 569
4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Description and Operation > Page 570
4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Diagrams
C2015
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 578
C286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 579
Ambient Light Sensor: Service and Repair
LIGHT SENSOR
Removal and Installation
1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove
the upper center instrument panel finish panel.
- Disconnect the electrical connector.
3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 586
C278
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 587
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 588
Brake Light Switch: Service and Repair
STOPLAMP SWITCH
Removal and Installation
CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm
secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or
installing the stoplamp switch, as misadjustment or damage to the switch may occur.
1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees
clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door
Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Removal and Installation
1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3.
Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 593
Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Removal and Installation
1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch
counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 594
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Removal and Installation
1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch
counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 595
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Removal and Installation
1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and
remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 600
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 601
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 602
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Door Ajar Switch, Driver Side Front
C526
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 605
C602
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 606
C715
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 607
C820
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 611
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 612
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 613
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations > Page 614
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 618
C205
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 619
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 620
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
Removal and Installation
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Locations
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 627
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 628
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 629
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 630
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 636
C2040
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 637
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 641
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 642
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 643
Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 644
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1 > Page 649
View 151-7 (Engine, Front - 4.6L)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor
C180
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 652
C1366
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft
Position Sensor > Page 653
C1367
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 654
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 655
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Diagrams
C1064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
665
Crankshaft Position Sensor: Diagrams
C101
C1120
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
666
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
667
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
668
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
672
C107
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
673
Engine Temperature Sensor: Description and Operation
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical CHT Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases., and the resistance
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.
The CHT sensor is installed in the 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 initiates a
fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern
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.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
674
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 678
Fuel Level Sensor: Diagrams
C434A
C434B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 679
Fuel Level Sensor: Description and Operation
FUEL LEVEL INPUT (FLI)
The FLI is a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 680
Fuel Level Sensor: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 681
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 682
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 683
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 684
All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 685
4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 686
4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation
Fuel Tank Pressure Sensor: Description and Operation
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and
Operation > Page 690
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents a danger or 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 cause 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.
1. Remove the evaporative emission (EVAP) canister.
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Operation > Page 691
2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor
electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick
connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank
pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the
evaporative emission system. See: Powertrain Management/Emission Control
Systems/Evaporative Emissions System/Testing and
Inspection/Evaporative Emission System Leak Test
8. Carry out the evaporative emission repair verification drive cycle. See: Powertrain
Management/Emission Control Systems/Evaporative
Emissions System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
695
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
696
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type
MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance 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 air flow.
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697
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described. One is located before the supercharger at the air cleaner for standard OBD/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 spark and to help determine charge air cooler (CAC) efficiency.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams
C108
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 701
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description
and Operation
Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Typical Manifold Absolute Pressure (MAP) Sensor
The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the
MAP sensor to measure how much exhaust gas is introduced into the intake manifold.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Locations
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Locations >
Page 708
C104
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Locations >
Page 709
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical EOT Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance changes 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 sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control
gains and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM begins reducing power by disabling engine cylinders.
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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 > Locations >
Page 710
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil.
- Install the drain plug and tighten to 26 Nm (19 lb-ft).
3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature
sensor.
- To install, tighten to 15 Nm (11 lb-ft).
5. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Fill the engine with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 715
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 716
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor (HO2S) #11 > Page 717
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22
C141
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 720
C142
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 721
C171
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #22 > Page 722
C172
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 723
Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a 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
a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by
providing the ground when the correct conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 726
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S)
is being serviced, remove the bolts and position the heat shield aside.
- To install, tighten to 20 Nm (15 lb-ft).
3. Disconnect the HO2S electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 727
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft).
5. To install, reverse the removal procedure.
- Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 728
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 729
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 730
3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to
ease removal.
Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft).
4. To install, reverse the removal procedure.
- Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams
C121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch > Page 736
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes 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 the transmission electronic pressure control (EPC) pressure during increased
engine load, for example, during parking maneuvers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 >
Description and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Description and Operation > Page 740
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 744
C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor > Page 747
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 748
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 749
Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 754
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 755
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 756
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 757
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 758
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 759
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 760
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 761
Symbols Part 5
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 762
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 763
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 764
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 765
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 766
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 767
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 768
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 769
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 770
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 771
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
> Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the 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 that is
generated.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
> Output Shaft Speed (OSS) Sensor > Page 776
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description
and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description
and Operation > Page 781
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 786
C2040
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 787
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 791
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 792
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 793
Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 794
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail
Pressure Transducer Sensor
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail
Pressure Transducer Sensor > Page 799
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail
Pressure Transducer Sensor > Page 800
View 151-5 (Engine, Front - 4.0L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagrams > Fuel Rail
Pressure/Temperature Sensor
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagrams > Fuel Rail
Pressure/Temperature Sensor > Page 803
C435
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation > Fuel Rail Pressure (FRP) Sensor
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation > Fuel Rail Pressure (FRP) Sensor > Page 806
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation > Page 807
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 811
Fuel Temperature Sensor: Description and Operation
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 812
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 816
C282
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 817
Inertia Fuel Shutoff Switch: Description and Operation
INERTIA FUEL SHUTOFF (IFS) SWITCH
Typical Inertia Fuel Shutoff (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shutoff 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's Literature for the location of the IFS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 818
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the
IFS switch
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 822
C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor > Page 825
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 826
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 827
Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 833
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
C180
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 836
C1366
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 837
C1367
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 838
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 839
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 843
Crankshaft Position Sensor: Diagrams
C101
C1120
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 844
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 845
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 846
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 Switch Lock Cylinder: Service and Repair
IGNITION LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the ignition lock cylinder. 2. To install, reverse the removal procedure.
- Lubricate the ignition lock cylinder during installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams
C108
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 854
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor, Left/Right
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor, Left/Right > Page 860
View 151-18 (Left Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor, Left/Right > Page 861
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor, Left/Right > Page 862
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Forward Crash Sensor, Left/Right > Page 863
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor, Left
C1465
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor, Left > Page 866
C1466
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor, Left > Page 867
Impact Sensor: Diagrams Side Impact Sensor
C567A
C567B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor, Left > Page 868
C644A
C644B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Forward Crash Sensor, Left > Page 869
C3248
C3249
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Diagrams > Page 870
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed.
In addition, make sure the area of the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct restraint system operation. If a vehicle equipped
with an SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Replace and correctly position the sensor or any other damaged SRS components
whether or not the air bag is deployed.
For these vehicles, the SRS uses up to 6 satellite sensors in addition to the RCM. The RCM is
mounted to the center tunnel beneath the console. All vehicles will have 2 front impact severity
sensors located in the front-center area of the vehicle, behind the grille mounted on the lower
radiator support. The first row impact sensors are located in each of the front doors behind the trim
panel. If the vehicle is equipped with safety canopies, there are 2 additional side impact sensors.
The 2 additional sensors are located on each C-pillar. Mounting orientation and torque is critical for
correct operation of all impact and rollover sensors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor
Impact Sensor: Service and Repair Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
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. Install and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To reduce the risk of 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 873
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Remove the 4 pin-type retainers and the lower radiator air deflector.
3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is
critical for correct system operation.
NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free
of foreign material.
- Note position of locator tab on sensor bracket for installation.
Remove the front impact severity sensor bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Disconnect the front impact severity sensor electrical connector and remove the sensor. 5. To
install, reverse the removal procedure. 6. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 874
Impact Sensor: Service and Repair Side Impact Sensor
C-Pillar
SIDE IMPACT SENSOR - C-PILLAR
Removal and 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Install a new sensor and correctly position the sensor or any other damaged SRS
components whether or not the air bag is deployed.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- RH side shown, LH similar.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 875
- The RH and LH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the system. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip.
4. Remove the 2 lower C-pillar trim panel retaining clips from the rear door opening sheet metal.
5. Position aside the lower C-pillar trim panel.
- Pull out on the quarter trim panel at the C-pillar to release the 3 retaining clips and access the
C-pillar side impact sensor.
6. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for
correct system operation.
NOTE: -
Note the position of the sensor and bracket locating tab for installation.
- Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign
material.
Remove the 2 bolts from the side impact sensor and bracket assembly. To install, tighten to 12 Nm (9 lb-ft).
7. Disconnect the electrical connector and remove the side impact sensor. 8. To install, reverse the
removal procedure. 9. Repower the system.
Front Door
SIDE IMPACT SENSOR - FRONT DOOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 876
Removal and 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Install a new sensor and correctly position the sensor or any other damaged SRS
components whether or not the air bag is deployed.
- 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 SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Driver side shown, passenger side similar.
1. Depower the system. 2. Remove the front interior door trim panel. 3. Detach the rearward lower
corner of the watershield on the door to expose the side impact sensor. 4. Disconnect the side
impact sensor electrical connector.
5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct
system operation.
CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position
the ground wire between the U-nut
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front Impact Severity Sensor > Page 877
and the sensor.
NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material.
- Note the position of the side impact sensor locating tabs for installation.
Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure. 7. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 882
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver
C3065
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 885
C3066
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Page 886
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the SRS, the front safety belt buckles are equipped with safety belt buckle switches. The
safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The
safety belt buckle switches (Hall-effect sensors) are located in the driver and front passenger safety
belt buckles. The safety belt buckle switches indicate to the RCM whether the safety belts are
buckled or unbuckled. The RCM uses this information in determining the deployment rate of the
dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety
belt buckle switch status to the instrument cluster module, which monitors the information to control
the safety belt warning indicator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tower Position
Sensor > Component Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Locations
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Occupant Classification Sensor Module
C3159
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Occupant Classification Sensor Module > Page 895
C3291
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Occupant Classification Sensor Module > Page 896
C3292
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > OCS System
Seat Occupant Sensor: Description and Operation OCS System
OCS System
The OCS system is found only on the front passenger seat. The front passenger OCS system is
comprised of the following: 2 OCS rails (weight sensors) that are mounted to each side of the seat
track; an OCS module (electronic control unit) which is mounted to the electrical bracket
underneath the seat cushion pan. The weight of any occupant or object on the front passenger seat
is electronically communicated to the OCS module.
The OCS system is also used for operation of the passenger Belt Minder. To deactivate or
reactivate the passenger Belt Minder feature, refer to Seat Belt Systems or the owner's literature.
The components that make up the OCS system, OCS module, inboard OCS rail and outboard OCS
rail are serviced separately.
When the front passenger seat is removed for service, the Zero Seat Weight Test must be carried
out after the installation of the front passenger seat. When a OCS system component is installed
new, the System Reset must be carried out after the installation of the front passenger seat. The
Zero Seat Weight Test and/or System Reset must be carried out only as instructed to do so.
OCS Rails (Weight Sensors)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > OCS System > Page 899
The components that make up the OCS system (OCS system module, inboard OCS rail and
outboard OCS rail) are serviced separately.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > OCS System > Page 900
Seat Occupant Sensor: Description and Operation Occupant Classification Sensor (OCS) System
OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM
The occupant classification system (OCS) system is standard equipment on all front passenger
seats.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 901
Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 902
Part 2
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.
- The occupant classification sensor rails have a built-in strain gauge which may operate incorrectly
if an occupant classification sensor rail is dropped by itself, dropped when installed to the front
passenger seat or dropped when installed to a front passenger seat track assembly. Use care
when handling an occupant classification sensor rail or when installed to the front passenger seat
of front passenger seat track assembly. Failure to follow these instructions may increase the risk of
personal injury or death in a crash.
- Do not disassemble the occupant classification sensor rail, tighten or loosen any of the nuts and
bolts installed to the occupant classification sensor rail body. Only the 8 bolts that attach the 2
occupant classification sensor rails to the seat track should be removed and installed. Failure to
follow these instructions may increase the risk of personal injury or death in a crash.
- Oil, grease, water or foreign material on or in the occupant classification sensor rail may cause
the supplemental restraint system to deploy incorrectly. Never allow oil, grease, water or foreign
material to get on or into the occupant classification sensor rail. Failure to follow these instructions
may increase the risk of personal injury or death in a crash.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- 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.
- Outboard occupant classification sensor (OCS) rail shown, inboard similar.
1. Remove the passenger seat and depower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 903
2. CAUTION: Push only on the tip of the occupant classification sensor (OCS) electrical connector
release tab to release the electrical
connector. Do not insert the tool too deep into the OCS electrical connector or damage to the
electrical connector may occur.
NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring
retainers for installation.
On the affected side, detach the 2 OCS rail wiring retainers. Then using a suitable tool, release the
tab and disconnect the OCS rail electrical connector.
3. If equipped, disconnect the power seat track motor electrical connector.
4. Move the seat to the forward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Remove the 2 rear bolts from the affected OCS rail.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 904
6. Move the seat to the rearward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail
shield and into the rear mounting point of the seat
track for installation.
Remove the 2 front bolts and the affected OCS rail and shield.
Installation
NOTE: If installing a new seat track, position the seat track where the seat will be in the rearward
most position before starting installation of the OCS rails.
1. WARNING: The occupant classification sensor rail shield is an aid to prevent foreign material
and contaminants from entering the
occupant classification sensor rail. Make sure the occupant classification sensor rail shield is
present, is not damaged and is correctly installed to the occupant classification sensor rail. Failure
to follow these instructions may increase the risk of personal injury or death in a crash.
NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to
the shield.
Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat
track while noting the correct installation of the OCS rail locator tab into the seat track.
2. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence
shown.
While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position
rear bolt. Tighten to 25 Nm (18 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 905
3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting
position front bolt.
- Tighten to 25 Nm (18 lb-ft).
4. Move the seat to the forward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Install the 2 rear OCS rail bolts.
- Tighten to 25 Nm (18 lb-ft).
6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during
removal.
Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring
retainers.
7. Center the seat track to the seat cushion pan.
- If equipped with a power seat track, apply power and ground to the pins shown.
8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger
seat and repower the supplemental restraints system (SRS). Do not prove out the SRS at this time.
10. Carry out the appropriate procedure after installation of an OCS system component.
- If installing the original OCS system component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. See: Restraint Systems/Air Bag
Systems/Testing and Inspection/Component Tests and General Diagnostics/Occupant
Classification Sensor (OCS) System Zero Seat Weight Test
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. See: Restraint Systems/Air Bag Systems/Service
and Repair
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Service and Repair
Seat Position Sensor: Service and Repair
SEAT POSITION SENSOR
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Power seat track seat position sensor shown, manual seat track position sensor similar.
1. Position the front seat to the rearmost and upward position. 2. Depower the system. 3.
Disconnect the seat position sensor electrical connector.
4. WARNING: The tightening torque of the seat position sensor retaining bolt is critical for correct
system operation.
NOTE: Note the position of the seat position sensor locating tab for installation.
Remove the bolt and the seat position sensor. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Service and Repair > Page 909
6. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Seat Track Position Sensor, Left
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Seat Track Position Sensor, Left > Page 914
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 915
C356
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair
Ignition Switch Lock Cylinder: Service and Repair
IGNITION LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the ignition lock cylinder. 2. To install, reverse the removal procedure.
- Lubricate the ignition lock cylinder during installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 929
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 930
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 931
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 932
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 933
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 934
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 935
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 941
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 942
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 943
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 944
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 945
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 946
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 947
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Page 948
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams
C121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch > Page 956
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes 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 the transmission electronic pressure control (EPC) pressure during increased
engine load, for example, during parking maneuvers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 960
C226
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 965
C226
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection
Tire Pressure Sensor: Testing and Inspection
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Smart Junction Box (SJB).
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees)
from the valve stem. Press and release the test
button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the
tire pressure sensor has been recognized by the SJB.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and
the entire procedure must be repeated.
8. Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will be
verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and
document them on the applicable warranty claim.
NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed SJB.
10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry
out the SJB On-Demand Self Test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor can be removed and installed without removing the strap or the cradle.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Dismount the tire only as
instructed.
Remove the tire from the wheel.
2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor locking clip can occur.
Using a pocket screwdriver, or similar tool, remove the sensor locking clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 973
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor can occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle.
4. Remove the sensor.
Assembly
1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor
installation.
NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise
when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the
cradle and pushing the opposite end of the sensor down onto the cradle.
2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the
sensor locking clip cannot be fully inserted, then
the sensor may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
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Monitoring System (TPMS) Sensor > Page 974
3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 975
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 976
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There
are several different strap kits available based on wheel diameter but all strap kits share the same
base part number.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. Remove the tire pressure monitoring system (TPMS) sensor.
2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and
gloves when removing the TPMS
band/strap. Failure to follow these instructions may result in personal injury.
Remove a factory installed strap in this sequence: 1
Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both
sides of the buckle approximately 25 mm (0.98 inch) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is
fully released from the worm gear.
^ Discard the strap.
3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle
and prying up.
Assembly
1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click"
noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of the sensor down onto the cradle.
2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to
remove the cradle adhesive strip residue.
NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the
valve stem.
Clean the area where the sensor and cradle are to be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 977
3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH
side when viewed from the curb side (beauty side)
of the wheel.
NOTE: The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel
drop well 180° from the valve stem.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is
positioned in the lowest spot possible for
correct sensor and cradle retention.
NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm
gear. ^
Tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 978
6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions
Brake Switch - TCC: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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985
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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986
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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988
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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989
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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990
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Switches - A/T > Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page
991
Symbols Part 4
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992
Symbols Part 5
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993
Brake Switch - TCC: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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994
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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995
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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996
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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997
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Overdrive Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1007
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1008
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1009
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1010
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1011
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1012
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1013
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1014
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1015
Overdrive Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1016
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1017
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1018
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1019
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1020
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1021
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1022
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 1023
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions
Throttle Position Sensor/Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1028
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1029
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1030
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1031
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1032
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1033
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1034
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1035
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1036
Throttle Position Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1037
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1038
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1039
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1040
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1041
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1042
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1043
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1044
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions
Transmission Mode Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1049
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1050
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1051
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1052
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1053
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1054
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1055
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1056
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1057
Transmission Mode Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1058
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1059
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1060
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1061
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1062
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1063
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 1065
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission
Control (TC) Switch
Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch
Transmission Control (TC) Switch
The transmission control (TC) switch is a momentary contact switch located on the selector lever
knob. Pushing the TC switch will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the
instrument panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission
Control (TC) Switch > Page 1068
Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS)
TRANSMISSION CONTROL SWITCH (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1069
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Removal
1. Remove the transmission selector lever knob.
2. Remove the transmission control switch from the knob.
Installation
1. Install the transmission control switch into the knob.
2. Install the transmission selector lever knob.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1074
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1075
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1076
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1077
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1078
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1079
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1080
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1081
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1082
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1083
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1084
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1085
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1086
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1087
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1088
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1089
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1090
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information
and Instructions > Page 1091
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1096
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1097
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1098
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1099
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1100
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1101
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1102
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1103
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1104
Transmission Speed Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1105
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1106
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1107
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1108
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1109
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1110
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1111
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1112
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1113
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 1114
C164
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1119
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1120
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1121
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1122
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1123
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1124
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1125
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1126
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1127
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1128
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1129
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1130
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1131
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1132
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1133
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1134
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1135
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1140
C284
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1141
Four Wheel Drive Selector Switch: Service and Repair
Mode Select Switch (MSS)
Mode Select Switch (MSS)
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
bezel. 3. With the center console cover open, remove the floor console center finish panel screws.
4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical
connector. 5. Remove the floor console center finish panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1142
6. Disconnect the electrical connector(s). Disengage the locking tangs and remove the mode select
switch (MSS) from the instrument panel center
finish panel.
7. To install, reverse the removal procedure.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 1148
Power Window Switch: Locations Window Adjust Switch
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 1149
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 1150
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 1151
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch
C980
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 1154
Power Window Switch: Diagrams Master Window Adjust Switch
C504A
C504B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 1155
Power Window Switch: Diagrams Window Adjust Switch
C604
C701
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 1156
C801
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1159
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1160
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 1161
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
Removal and Installation
1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release
the clips. 3. Disconnect the window control switch electrical connectors from the window control
switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations > Page 1166
C138
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Multifunction Switch
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Multifunction Switch > Page 1171
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Multifunction Switch
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 1174
C2347
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1177
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1178
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 1179
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 1180
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 1184
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1187
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 1188
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Page 1189
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Testing and Inspection > Page 1190
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1196
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1197
Alignment: Specifications General Specifications
General Specifications
General Specifications (Part 1)
General Specifications (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1198
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1199
Alignment: Specifications
General Specifications
General Specifications
General Specifications (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 1200
General Specifications (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1201
Alignment: Description and Operation
Suspension System
The front camber and caster are adjusted by loosening the upper control arm bolts which will allow
the upper arm to be moved in the slotted frame holes. The LF caster can be adjusted by loosening
the lower control arm rearward nut to allow the lower arm to be moved in the slotted frame hole.
Front toe is adjusted by the use of the front wheel spindle tie rods. The rear camber is adjusted by
replacing the upper arm inboard flag nut with a non-flag nut to allow the arm to be adjusted in the
slotted frame holes. The rear toe is adjusted through the use of the rear toe link cam bolt.
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
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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1202
Positive Toe (Toe In)
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.
Ride Height
Front Ride Height Measurement
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1203
Rear Ride Height Measurement
Thrust Angle (Dogtracking)
Thrust Angle (Dogtracking)
Thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the
chassis. Heavily crowned roads can give the illusion of incorrect thrust angle.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1204
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, such as wind or road camber.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front
Alignment: Service and Repair Camber and Caster Adjustment - Front
Camber and Caster Adjustment - Front
1. Using alignment equipment and the manufacturer's instructions, measure the front caster and
camber. 2. Loosen the upper arm bolt(s) and adjust the caster and camber settings. Refer to the
chart.
^ When making adjustments that require moving both the front and the rear of the upper arm, move
both ends of the arm equally.
3. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster and camber
settings are not disturbed while tightening the
bolt(s).
Tighten the upper arm bolt(s) to 150 Nm (111 ft. lbs.)
4. NOTE: A caster split adjustment can be made by loosening the LF lower arm rearward nut and
adjusting the rear of the LF lower arm.
Remove and discard the LF lower control arm rearward nut.
5. NOTE: Do not fully tighten the nut and bolt at this time.
Install a new LF lower control arm rearward nut.
6. Position the LF lower control arm until the caster split is within specification.
7. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster settings are
not disturbed while tightening the nut.
Tighten the LF lower control arm rearward nut to 200 Nm (148 ft. lbs.)
8. Recheck the camber and caster, adjust as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1207
9. Check and, if necessary, adjust the front toe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1208
Alignment: Service and Repair Toe Adjustment - Front
Toe Adjustment - Front
1. Using alignment equipment and the manufacturer's instructions, measure the front toe. 2. Start
the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding
device, lock the steering wheel in the straight ahead position.
4. NOTE: Do not allow the steering gear bellows to twist when the front wheel inner tie rod is
rotated.
Remove the clamps.
5. Loosen the tie-rod jam nuts.Rotate the front wheel inner tie rods until the toe setting is within
specification.
6. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the
steering gear bellows can occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the nuts.
Tighten the tie-rod jam nuts to 70 Nm (52 ft. lbs.)
7. Install the clamps. 8. Recheck the toe settings and adjust if necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1209
Alignment: Service and Repair Toe Adjustment - Rear
Toe Adjustment - Rear
1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. 2. Start
the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding
device, lock the steering wheel in the straight ahead position. 4. Loosen the rear toe link inboard
nut.
5. Rotate the rear toe link cam bolt until the toe setting is within specification.
6. NOTE: Make sure the toe settings are not disturbed while tightening the nut.
While holding the adjustment cam bolt, tighten the toe link inboard nut. ^
Tighten to 275 Nm (202 ft. lbs.)
7. Recheck the toe settings and adjust if necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front > Page 1210
Alignment: Service and Repair Camber Adjustment - Rear
Camber Adjustment - Rear
1. Index-mark the upper arm inboard bolt to the frame.
2. NOTE: The upper arm inboard flag nut must be removed and replaced with a non-flag nut to
allow for the adjustment of the arm in the frame slot.
Remove and discard the upper arm inboard bolt and flagnut. ^
Install a new non-flagnut.Using alignment equipment and the manufacturer's instructions, measure
the rear camber.
3. NOTE: The weight of the vehicle must be off of the wheels in order to adjust the rear camber.
NOTE: For camber adjustment, 1 mm (0.03 inch) of movement equals 0.24 degrees of camber.
NOTE: To decrease the camber, move the upper arm inward. To increase the camber, move the
upper arm outward.
Position the upper arm until the camber setting is within specification.
4. NOTE: Make sure that the camber settings are not disturbed while tightening the nut.
Tighten the upper arm inboard nut to 250 Nm (185 ft. lbs.)
5. Recheck the camber settings and adjust as necessary. 6. Check and, if necessary, adjust the
rear toe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Fuel Pressure
Key on, engine off.................................................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
............................................................ 630-850 RPM
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 1222
Exploded View
Removal and Installation
NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector.
Vehicles equipped with a 4.0L (SOHC) engine
1. Detach the wiring harness retainer from the air cleaner outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 1223
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and
remove the air cleaner cover. 5. Remove the air cleaner element.
6. NOTE: Clean the inside of the air cleaner tray.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
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.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow
it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to
make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key
and wait 3 seconds to pressurize the fuel system.
Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame
scuff plate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications > Page 1231
Firing Order: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Number One Cylinder: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1240
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1241
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1242
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1243
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1244
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1245
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1246
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1247
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1248
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1249
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 1250
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions 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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > General Specifications
Spark Plug: Specifications General Specifications
Item.......................................................................................................................................................
..............................................................Specification
Spark plug gap (not adjustable)............................................................................................................
.....................................1.02-1.28 mm 0.040-0.050 in)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > General Specifications > Page 1253
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1254
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
....................................................................... PZT1F
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1255
Spark Plug: Testing and Inspection
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1256
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1257
Spark Plug: Service and Repair
SPARK PLUGS
Exploded View
Removal and Installation
1. Disconnect the ignition coil electrical connectors. 2. Remove the ignition coil bolts.
- To install, tighten to 5 Nm (44 lb-in).
3. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease
removal.
Remove the ignition coils.
4. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is re-used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
5. CAUTION: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark
plug is adjusted. Install a new spark
plug if the gap is out of specification.
Inspect the spark plugs. Install new spark plugs as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1258
6. To install, reverse the removal procedure.
- Apply a light film of brake caliper grease to the inside of the coil boots before installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1262
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 5 compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
If one or more cylinders read 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 2 adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may be
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1263
leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is at least 75% of the highest reading.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start
Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05.
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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1272
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start
Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05.
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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 09-9-7 > May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1278
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Drive Belt: > 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Drive Belt: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1284
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Drive Belt: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1285
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Drive Belt: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1291
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Drive Belt: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1292
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1293
Drive Belt: Diagrams
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
Accessory Drive
Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt,
tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping
mechanism will occur. Do not apply any fluids or belt dressing to the accessory drive belt or
pulleys.
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
Visual Inspection Chart
Visual Inspection Chart
3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, power steering
cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine.
4. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered
acceptable. If damage exceeds the acceptable limit or
any chunks are found to be missing from the ribs, a new belt must be installed.
Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be
considered acceptable. If cracks exceed this standard, install a new belt.
6. The condition of the V-ribbed drive belt should be compared against the illustration and
appropriate action taken.
1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new
belt is not required.
2 Longer deposit areas building up to 50% of the rib height. This is not considered a concern but it
can result in excessive noise. If noise is apparent, install a new belt.
3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a new belt.
V-Ribbed Serpentine Belt With Piling
NOTE: Piling is an excessive buildup in the V-grooves of the belt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1296
V-Ribbed Serpentine Belt With Piling
7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this,
install a new accessory drive belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
V-Ribbed Serpentine Belt With Chunks Of Rib Missing
8. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See:
Symptom Related Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1297
Drive Belt: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1298
Symptom Chart (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1299
Drive Belt: Component Tests and General Diagnostics
Drive Belt - Noise/Flutter
Drive Belt - Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley
runout. It can be the result of a damaged or incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on
an accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start-up and shut down or during very rapid
engine acceleration and decelerations, such as:
^ wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions.
^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual
transmissions.
These special short-term transient events are expected, and are due to the higher system inertias
required to meet the electrical and cooling demands on today's vehicle systems. Constant or
reoccurring drive belt squeal can occur:
^ if the A/C discharge pressure goes above specifications:
^ the A/C system is overcharged.
^ the A/C condenser core airflow is blocked.
^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after
several minutes) exceeds specifications.
^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories
should be rotatable by hand in the unloaded condition. If not, inspect the accessory.
^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has
been exposed to fluid contamination during vehicle operation, such as leaks from the power
steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with
clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a
localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt
and pulleys should be washed with soap and water immediately (prior to starting the engine), and
rinsed with clean water.
^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive
belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will
release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal
installation wear range window, install a new accessory drive belt.
^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding.
Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.
Drive Belt - Incorrect Installation
Drive Belt - Incorrect Installation
CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can
cause the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt
tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive
belt.
Incorrect Installation
Incorrect Installation
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Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 1300
Correct Installation
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the
accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur.
Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking
condition exists, proceed with the following:
^ Visually check the accessory drive belt tensioner for damage, especially the mounting pad
surface. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will
be out of position. This will result in chirp and squeal noises.
^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.
^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any
interference that would prevent the component from mounting correctly. Correct any interference
condition and recheck the accessory drive belt tracking.
^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware
to specification. Recheck the accessory drive belt tracking.
Belt Tensioner - Mechanical
Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for
tensioner stick, grab or bind.
1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under
Description and Operation.
2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Using a suitable, commercially available serpentine belt tensioner release tool, release the tension
on the belt and detach the accessory drive belt in the area of the tensioner.
3. Using a suitable, commercially available serpentine belt tensioner release tool, move the
tensioner from its relaxed position, through its full stroke
and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that
there is tension on the tensioner spring.
4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition.
Install a new accessory drive belt tensioner if
necessary.
5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination
and repair any leaks. Install a new accessory drive
belt tensioner as necessary.
6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner
dynamically. If the accessory drive belt tensioner
does not meet the above criteria, install a new tensioner.
Belt Tensioner - Dynamics
Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as
follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory
drive tensioner should move (respond) when the air
conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory
drive belt tensioner movement is excessive without air conditioning clutch cycling or engine
acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can
cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a
new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory
drive belt tensioner.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1301
Drive Belt: Service and Repair
Accessory Drive Belt - 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. 2. Rotate the accessory drive belt tensioner clockwise and
remove the accessory drive belt.
3. To install, reverse the removal procedure.
^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.6L (3V).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Page 1307
Exploded View
Removal and Installation
NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector.
Vehicles equipped with a 4.0L (SOHC) engine
1. Detach the wiring harness retainer from the air cleaner outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Page 1308
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and
remove the air cleaner cover. 5. Remove the air cleaner element.
6. NOTE: Clean the inside of the air cleaner tray.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
This vehicle is not factory equipped with a Cabin Air Filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and
Repair
Evaporative Canister Filter: Service and Repair
DUST SEPARATOR
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
NOTE: Use only water-based lubricants on the vapor hoses.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the fuel vapor hose from the dust separator. 4. Disconnect the fuel filler pipe vapor
hose from the dust separator. 5. Remove the bolt and the dust separator.
- To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure.
- Lubricate the vapor hoses with a water-based lubricant to ease installation.
7. Leak test the evaporative emission system. See: Powertrain Management/Emission Control
Systems/Evaporative Emissions System/Testing and
Inspection/Evaporative Emission System Leak Test
8. Carry out the evaporative emission repair drive cycle. See: Powertrain Management/Emission
Control Systems/Evaporative Emissions
System/Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
Fluid Pan, Gasket and Filter
Material
Removal
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the fill plug fluid level indicator assembly located on
the passenger side front portion of the transmission case. Removal of the plug will
relieve any vacuum that might have built up in the transmission. This will allow the fluid pan to be
easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the fluid to drain.
4. Remove the fluid pan gasket.
5. Remove and discard the transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page
1318
6. Clean and inspect the transmission fluid pan and magnet.
Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new
transmission fluid filter and seal assembly. The fluid filter may be reused if no excessive
contamination is indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case,
carefully remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with clean
automatic transmission fluid.
3. NOTE: The fluid filter may be reused if no excessive contamination is indicated.
Install a new transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page
1319
4. Position the magnet in the transmission fluid pan.
5. NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
6. Install the fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 ft. lbs.)
7. Using the refill procedure, fill the transmission with clean automatic transmission fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
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.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow
it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to
make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key
and wait 3 seconds to pressurize the fuel system.
Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame
scuff plate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair
Coolant Line/Hose: Service and Repair
Coolant Crossover Manifold Assembly
Coolant Crossover Manifold Assembly (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Page 1328
Coolant Crossover Manifold Assembly (Part 2)
Removal and Installation
1. Disconnect the battery ground cable. 2. Drain the engine cooling system. For additional
information, refer to Cooling System Draining, Filling and Bleeding. 3. Remove the intake manifold.
4. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator
pulley.
5. Disconnect the electrical connector. 6. Loosen the generator nuts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Page 1329
^ To install, tighten to 25 Nm (18 ft. lbs.).
7. Remove the generator bracket-to-coolant crossover bolts, and position the generator, bracket
and wiring harness aside as an assembly.
^ To install, tighten to 10 Nm (89 inch lbs.).
8. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 9. Disconnect
the heater hose from the coolant crossover manifold assembly.
10. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 11. Remove
the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets.
^ To install, tighten to 10 Nm (89 inch lbs.).
12. To install, reverse the removal procedure.
^ Install new gaskets.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1338
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 1339
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
1345
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
1346
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Heater Outlet and Inlet Line - Front
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front
AUXILIARY HEATER OUTLET AND INLET LINE - FRONT
Removal and Installation
1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4.
Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release
the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3
auxiliary line bracket nuts.
- To install, tighten to 6 Nm (53 lb-in).
7. Remove the 3 auxiliary line bracket bolts.
- To install, tighten to 6 Nm (53 lb-in).
8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines.
10. To install, reverse the removal procedure. 11. Fill the engine cooling system,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Heater Outlet and Inlet Line - Front > Page 1349
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear
AUXILIARY HEATER OUTLET AND INLET LINE - REAR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the
spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type
retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose
clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and
disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Auxiliary
Heater Outlet and Inlet Line - Front > Page 1350
- To install, tighten to 8 Nm (71 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12.
To install, reverse the removal procedure. 13. Fill the engine cooling system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When Compressor Cycles
Hose/Line HVAC: Customer Interest A/C - Thump Noise When Compressor Cycles
TSB 06-12-12
06/26/06
A/C COMPRESSOR THUMP NOISE WITH 4.0L V-6
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Explorer Sport Trac vehicles built with a
4.0L V-6 engine and built before 2/7/2006, may exhibit an intermittent thump or similarly described
noise transmitted into the passenger compartment in A/C / Auto / Defrost modes, when the A/C
compressor engages. The noise may occur when the A/C suction line makes contact with the sheet
metal cowl in the engine compartment. The identified thump or similar noise may be audible behind
the instrument cluster when driving and may also only occur intermittently under hard
accelerations.
ACTION Use the following Service Procedure to insulate the A/C suction line from contact with the
cowl. Apply an adhesive foam block between the A/C suction line and cowl sheet metal in the area
of potential contact.
NOTE
A/C COMPRESSORS SHOULD NOT BE REPLACED TO CORRECT THIS CONDITION.
SERVICE PROCEDURE
1. Visually inspect for the presence of a foam block between the suction line and cowl shown in
Figure 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When Compressor Cycles
> Page 1359
2. If the foam block is already present, ensure that it is properly positioned to insulate the line from
the cowl (Figure 2). If the foam block is present and positioned properly do not continue with this
TSB.
3. If the foam block is missing, install one (1). The adhesive side should face the sheet metal of the
cowl and should be installed in line with the center of the A/C line ferrel (Figure 2).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061212A 2006 Explorer/Mountaineer, 0.2 Hr.
2007 Explorer Sport Trac 4.0L: Install Or Position Foam Block
DEALER CODING
CONDITION
BASIC PART NO. CODE
19N617 43
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When
Compressor Cycles
Hose/Line HVAC: All Technical Service Bulletins A/C - Thump Noise When Compressor Cycles
TSB 06-12-12
06/26/06
A/C COMPRESSOR THUMP NOISE WITH 4.0L V-6
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Explorer Sport Trac vehicles built with a
4.0L V-6 engine and built before 2/7/2006, may exhibit an intermittent thump or similarly described
noise transmitted into the passenger compartment in A/C / Auto / Defrost modes, when the A/C
compressor engages. The noise may occur when the A/C suction line makes contact with the sheet
metal cowl in the engine compartment. The identified thump or similar noise may be audible behind
the instrument cluster when driving and may also only occur intermittently under hard
accelerations.
ACTION Use the following Service Procedure to insulate the A/C suction line from contact with the
cowl. Apply an adhesive foam block between the A/C suction line and cowl sheet metal in the area
of potential contact.
NOTE
A/C COMPRESSORS SHOULD NOT BE REPLACED TO CORRECT THIS CONDITION.
SERVICE PROCEDURE
1. Visually inspect for the presence of a foam block between the suction line and cowl shown in
Figure 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When
Compressor Cycles > Page 1365
2. If the foam block is already present, ensure that it is properly positioned to insulate the line from
the cowl (Figure 2). If the foam block is present and positioned properly do not continue with this
TSB.
3. If the foam block is missing, install one (1). The adhesive side should face the sheet metal of the
cowl and should be installed in line with the center of the A/C line ferrel (Figure 2).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061212A 2006 Explorer/Mountaineer, 0.2 Hr.
2007 Explorer Sport Trac 4.0L: Install Or Position Foam Block
DEALER CODING
CONDITION
BASIC PART NO. CODE
19N617 43
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line
Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line
COMPRESSOR TO CONDENSER DISCHARGE LINE
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air
cleaner and air cleaner outlet tube. 4. Remove the compressor-to-condenser discharge line bracket
nut and detach the bracket.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the compressor outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).
6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1368
7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet
fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected
from the cooling module.
Detach the 2 compressor-to-condenser discharge line clips at the cooling module.
10. Remove the compressor-to-condenser discharge line. 11. To install, reverse the removal
procedure.
- Install a new gasket seal and O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1369
Hose/Line HVAC: Service and Repair Condenser to Evaporator Line
CONDENSER TO EVAPORATOR LINE
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
All vehicles
1. Remove the air cleaner and air cleaner outlet tube. 2. Recover the refrigerant. 3. Remove the
powertrain control module (PCM) and PCM bracket. 4. Disconnect the RH wheel speed sensor
electrical connector and detach the wire harness from the condenser-to-evaporator line bracket.
Vehicles equipped with 4.6L engine
5. Remove the suction accumulator-to-compressor line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
All vehicles
6. Disconnect the evaporator core orifice access fitting.
- Discard the O-ring seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1370
7. Remove the condenser-to-evaporator line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
8. Remove the condenser outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
9. Disconnect the auxiliary evaporator inlet line fitting (if equipped).
- Discard the O-ring seals.
10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket
nut at the dash panel and detach the bracket.
- To install, tighten to 6 Nm (53 lb-in).
12. Disconnect the evaporator inlet fitting.
- Discard the O-ring seals.
13. Remove the rear portion of the condenser-to-evaporator line. 14. To install, reverse the removal
procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
15. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1371
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1372
Part 2
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system, except when there is physical evidence of contamination from a failed A/C compressor or
damage to the accumulator.
1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting.
- Discard the O-ring seals.
3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front
fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and
disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 3 auxiliary line bracket nuts.
- To install, tighten to 6 Nm (53 lb-in).
8. Remove the 3 auxiliary line bracket bolts.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 6 auxiliary line brackets.
10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal
procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1373
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor to Condenser Discharge Line > Page 1374
Part 2
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the accumulator.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the
spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type
retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front
fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
8. Remove the auxiliary line bracket nut.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet
line.
- Discard the thermostatic expansion valve (TXV) filter.
12. To install, reverse the removal procedure.
- Install new O-ring seals.
- Install a new TXV filter.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
13. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair
Power Steering Line/Hose: Service and Repair
Power Steering Pump to Steering Gear Pressure Line
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Page 1378
Removal
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the power steering pump pulley. 3. Remove the
steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the fluid cooler
return line from the steering gear.
^ Discard the O-ring seal.
5. Disconnect the pressure line from the steering gear.
^ Discard the O-ring seal.
6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Page 1379
7. Remove the pressure line-to-crossmember retainer bracket bolt. 8. Disconnect the pressure
line-to-pump fitting.
^ Remove and discard the Teflon(R) O-ring seal.
9. Remove the pressure line.
Installation
1. NOTE: A new Teflon(R) O-ring seal must be installed.
Using the special tool, install a new Teflon(R) O-ring seal on the pressure line fitting.
2. Position the pressure line and connect the pressure line-to-pump fitting.
^ Tighten to 65 Nm (48 ft. lbs.)
3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L).
^ Tighten to 11 Nm (8 ft. lbs.)
4. NOTE: New O-rings must be installed whenever the power steering lines are disconnected.
Install a new O-ring seal and position the pressure line to the steering gear.
5. Install the pressure line bracket-to-crossmember bolt.
^ Tighten to 12 Nm (9 ft. lbs.)
6. Install a new O-ring seal and position the power steering gear-to-fluid cooler return hose to the
steering gear. Rotate the steering line clamp plate
into position.
7. Install the steering line clamp plate nut.
^ Tighten to 25 Nm (18 ft. lbs.)
8. Install the power steering pump pulley. 9. Fill the power steering system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
BRAKE FLUID
Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid
Ford Part Number ................................................................................................................................
................................................... PM-1 or PM-1-C Ford Specification
......................................................................................................................................................
ESA-M6C25-A or WSS-M6C62-A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity .................................................................................................................................
............................................ 13.9 quarts (13.2 liters)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1388
Coolant: Fluid Type Specifications
ENGINE COOLANT
Motorcraft Premium Gold Engine Coolant (yellow-colored)
Ford Part Number ................................................................................................................................
.................................................................. VC-7-B Ford Specification ................................................
................................................................................................................................ WSS-M97B51-A1
Note: Add the coolant type originally equipped in your vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid 5R55S ..................................................................................................................
............................................................................. 12.4 quarts (11.7 liters) 6R60 ................................
..............................................................................................................................................................
.... 11.2 quarts (10.6 liters)
Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler
size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should
be checked by a qualified technician.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1393
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
5R55S ..................................................................................................................................................
............................................. MERCON V XT-5-QM 6R60 ..................................................................
............................................................................................................................. MERCON SP
XT-6-QSP
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill
Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Special Tool(s)
Material
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. NOTE: Some fluid leakage may occur when removing the fluid fill plug.
Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion
of the transmission case. Removal of the plug will relieve any vacuum that might have built up in
the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are
removed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1396
3. Remove the transmission fluid pan and allow the fluid to drain.
4. Install the transmission fluid pan.
^ Tighten to 14 Nm (10 ft. lbs.)
Transmission Fluid Refill
CAUTION: This procedure contains the air purge steps required to purge air from the cooling
system. This procedure is NOT intended for use with the Transmission Fluid Level Check.
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result.
CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot
during this procedure.
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level
should be checked.
NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure.
^ Adding 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission is an initial fill
enabling you to start the engine.
^ The cold level range shown in the procedure allows the vehicle to be driven.
^ The vehicle should be driven to allow the transmission fluid temperature to reach 85°C - 88°C
(185°F - 190°F) in order to purge the air from the transmission cooling system.
^ Fill the transmission fluid to the fill range on the fluid level indicator at the normal operating range
80°C - 85°C (175°F - 185°F).
1. NOTE: The transmission will need 3.3L (3.5 qt) of clean automatic transmission fluid added to
the transmission as an initial fill if:
^ the transmission has been overhauled.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1397
^ a new Mechatronic assembly has been installed.
^ the transmission fluid pan or fluid filter have been removed.
Using the special tool, add 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission
through the fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in
this procedure.
2. Check the transmission fluid level cold.
1 The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C - 43°C (90°F 110°F).
^ Using the scan tool and the engine running, place the transmission selector lever in each gear
position and hold approximately 5 seconds. Place the transmission selector lever in PARK, with the
engine at idle (600 - 750 rpm).
3. Separate the fluid level indicator from the fill plug.
4. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug
hole to check the fluid level. Repeat this until a
consistent reading is established.
5. Add clean transmission fluid to the cold level location as shown in the illustration.
6. Install the fluid fill plug.
^ Tighten to 35 Nm (26 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1398
7. While driving the vehicle, use the scan tool to verify that the transmission fluid temperature has
reached a temperature of 88°C (190°F). This will
circulate the transmission fluid through the torque converter and the cooling system, eliminating
any trapped air in the cooling system. ^
With the engine idling (600 - 750 rpm) in PARK, verify that the transmission fluid temperature is
between 80°C - 85°C (175°F - 185°F).
8. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front
portion of the transmission case.
9. Separate the fluid level indicator from the fill plug.
10. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug
hole to check the fluid level. Repeat this until a
consistent reading is established.
11. Using the scan tool verify that the transmission fluid temperature is between 80°C - 85°C
(175°F - 185°F). The fluid level must be at the upper
level of the crosshatch mark.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1399
12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid in this procedure.
Install the fluid fill plug. ^
Tighten to 35 Nm (26 ft. lbs.)
Adding Additional Transmission Fluid
NOTE: To get an accurate fluid level reading the engine should be idling (600 - 750 rpm) in PARK.
1. Install the special tool into the fluid fill hole.
2. Fill the special tool with approximately 0.47L (1 pt) of clean automatic transmission fluid.
3. Hang the special tool under the vehicle, upright and close to the transmission.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1400
4. Connect the special tools.
^ Connect the open end of the fluid hose from the special tool onto the special tool from the
transmission case.
5. 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.
6. NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the
crosshatch mark.
Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this
until a consistent reading is established.
7. Using the scan tool verify that the transmission fluid temperature is between 80°C - 85°C (175°F
- 185°F). The fluid level must be at the upper
level of the crosshatch mark.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1401
8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in
this procedure.
Install the fluid fill plug. ^
Tighten to 35 Nm (26 ft. lbs.)
Removing Transmission Fluid
NOTE: To get an accurate fluid level reading the engine should be idling (600 - 750 rpm) in PARK.
1. If the transmission is overfilled, fluid must be removed to the correct level. Use the special tools
to extract any excessive fluid.
2. Using the scan tool, verify that the transmission fluid temperature is between 80°C - 85°C (175°F
- 185°F). The fluid level must be at the upper
level of the crosshatch mark. Reinstall the fluid level indicator only back into the fill plug hole to
check the fluid level. Repeat this until a consistent reading is established.
3. Install the fluid fill plug.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1402
^ Tighten to 35 Nm (26 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1403
Fluid - A/T: Service and Repair Transmission Fluid Level Check
Transmission Fluid Level Check
Special Tool(s)
Material
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result.
CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot
during this procedure.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city
traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate
reading.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level
should be checked.
NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch
mark.
NOTE: If the installation of a new transmission fluid cooler, cooler lines have been carried out the
vehicle must be driven to get the transmission fluid to a temperature of 88°C (190°F) in order to
purge the air from the cooling system.
1. With the engine running, place the transmission selector lever in each gear position and hold
approximately 5 seconds. Place the transmission
selector lever in PARK.
2. With the engine idling (600 - 750 rpm) in PARK, position it on a hoist. For additional information,
refer to Maintenance/Service and Repair. 3. Remove the fluid fill plug fluid level indicator assembly,
located on the passenger side front portion of the transmission case.
4. Separate the fluid level indicator from the fill plug.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1404
5. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug
hole to check the fluid level.
6. Using the scan tool, verify that the transmission fluid temperature is between 80°C - 85°C (175°F
- 185°F). Do not overfill the transmission. The
fluid level must be at the upper level of the crosshatch mark.
7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid.
Install the fluid fill plug. ^
Tighten to 35 Nm (26 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Drain and Refill > Page 1405
Fluid - A/T: Service and Repair Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler - Backflushing and Cleaning
Material
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the cooler lines and install a new cooler before placing the transmission in use.
CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the
cooling system or transmission could occur.
1. Install a new transmission fluid cooler if any fluid leaks are indicated or a major metallic failure is
indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines.
3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting
them to the cleaner.
Connect the cleaner pressure and return lines appropriately. 1
Connect the pressure line to the fluid cooler inlet tube.
2 Connect the return line to the fluid cooler outlet tube.
3 Place the outlet end of the return line in the fluid tank reservoir.
4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system.
Switch the fluid pumps ON. Allow the fluid to circulate a minimum of 5 minutes.
5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7.
Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove
the rubber hoses from the fluid cooler tubes.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
Front Differential
Differential Oil Capacity
Refill .....................................................................................................................................................
........................................................... 2.7 pts. (1.3L)
Rear Differential
Differential Oil Capacity
Refill .....................................................................................................................................................
........................................................... 3.5 pts. (1.7L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 1410
Fluid - Differential: Fluid Type Specifications
Front Differential
Differential Fluid Type
Type ................................................................................................................................................
Motorcraft SAE 80W-90 Premium Rear Axle Lubricant Ford Part Number .........................................
................................................................................................................................................
XY-80W90-QL Ford Specification .......................................................................................................
............................................................................... WSP-M2C197-A
Rear Differential
Differential Fluid Type
Type ................................................................................................................................. SAE
75W-140 High Performance Synthetic Rear Axle Lubricant
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page
1411
Fluid - Differential: Service and Repair
Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear
Differential Draining and Filling
Special Tool(s)
Material
Fluid Check
1. NOTE: Before removing, clean the area around the filler plug.
Remove the fill plug.
Fluid Drain and Fill
1. Remove the drain plug. 2. Clean and install the drain plug.
^ Tighten to 34 Nm (25 ft. lbs.)
3. Fill the axle to the bottom of the fill plug hole. 4. Install the fill plug.
^ Tighten to 34 Nm (25 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Case Capacity .......................................................................................................................
.................................................................... 1.5 Quarts
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 1416
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page
1417
Fluid - Transfer Case: Service and Repair
Transfer Case Draining and Filling
Material
1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed.
Remove the drain plug and drain the fluid. ^
Position a suitable drain pan under the transmission.
2. Clean and install the drain plug.
^ To install, tighten to 20 Nm (15 ft. lbs.)
3. CAUTION: Incorrect fluid fill can result in transfer case failure.
NOTE: Fill the transfer case with the vehicle on a level surface.
NOTE: The fluid level should be just below the fill plug.
NOTE: Clean the area around the fill plug.
Remove the fill plug. Using a suitable oil suction gun, fill the transfer case to the correct level with
the specified fluid. ^
The fluid must be just below the fill plug hole. Because the fluid can be reached with a finger does
not mean the fluid is at the correct level. Make sure the fluid is level with the filler opening for the
correct fluid level.
4. Clean and install the fill plug.
^ To install, tighten to 15 Nm (11 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil Capacity
Includes filter change ...........................................................................................................................
............................................................... 6.0L (6.5 qt)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1422
Engine Oil: Fluid Type Specifications
Engine Oil
U.S. .........................................................................................................................................
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada
....................................................................................................................................................
Motorcraft SAE 5W-20 Super Premium Motor Oil
Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the
API Certification mark and meet the requirements of Ford Specification WSS-M2C930-A.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications
Power Steering Fluid: Specifications
POWER STEERING FLUID
Motorcraft MERCON Multi-Purpose ATF
Ford Part Number ................................................................................................................................
.............................................................. MERCON Ford Specification ................................................
............................................................................................................................................ XT-2-QDX
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Page
1426
Power Steering Fluid: Testing and Inspection
Power Steering Fluid Leak Test
NOTE: This test should only be carried out if a leak in the system has not been detected during a
thorough visual inspection. Refer to Inspection and Verification. See: Steering and
Suspension/Steering/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection
and Verification
1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2.
Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power
steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap
on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using
the vacuum pump, apply 68 - 85 kPa (20 - 25 in-Hg) of vacuum to the power steering system. 6.
Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa
(0.88 in-Hg) a leak is present. 7. Remove the vacuum pump.
8. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to
the power steering pump can occur.
Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C
(165 - 176°F) by rotating the steering wheel fully to the left and right several times.
9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not
evident, add the specified UV fluorescent tracer dye
to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89 L (2 qt) of power
steering fluid.
10. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to
the power steering pump can occur.
Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C
(165 - 176°F) by rotating the steering wheel fully to the left and right several times.
11. NOTE: On vehicles with rack and pinion steering gear, it may be necessary to remove the
bellows boot clamp from the steering gear bellows
boots to inspect for internal steering gear leaks.
Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Capacity
Capacity without auxiliary climate control.............................................................................................
......................................................0.88 kg (31 oz) Capacity with auxiliary climate control...................
.....................................................................................................................................1.33 kg (47 oz)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1431
Refrigerant: Fluid Type Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Type
R134a Refrigerant YN-19 ....................................................................................................................
.................................................. WSH-M17B19-A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1432
Refrigerant: Description and Operation
REFRIGERANT SYSTEM DYE
Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will
dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye
after flushing or filtering the refrigerant system because a new suction accumulator is installed as
part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if
more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation,
hose rupture or other damage.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Oil Capacity
Capacity without auxiliary climate control.............................................................................................
......................................................266 ml (9 fl oz) Capacity with auxiliary climate control...................
...................................................................................................................................473 ml (16 fl oz)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 1437
Refrigerant Oil: Fluid Type Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Oil Type
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D
............................................................................................................. WSH-M1C231-B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer
Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > Customer
Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1446
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > By
Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > By
Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1452
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 1458
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake System
Bleeding
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Special Tools
Material
Master Cylinder Bleeding
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in personal injury.
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
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 new installation,
air may get into the system and cause spongy brake pedal feel. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be gravity bled,
manually bled or bled using pressure bleeding equipment.
1. NOTE: When a new brake master cylinder has been installed or the system has been emptied or
partially emptied, it should be primed to prevent
air from getting into the system.
Disconnect the brake master cylinder tubes.
2. NOTE: Original equipment tubes are not intended to be used during this procedure.
Install the 2 short brake tubes with the ends submerged in the brake master cylinder reservoir and
fill the brake master cylinder reservoir with clean, specified brake fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake System
Bleeding > Page 1461
3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air
bubbles. 4. Remove the 2 short brake tubes and install the 2 master cylinder brake tubes. 5. Bleed
each brake tube at the brake master cylinder as follows:
1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant
maintain pressure on the brake pedal while tightening the brake tube fitting.
3 Repeat this operation until clear, bubble-free fluid comes out.
4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front
brake tube.
6. While the assistant maintains pressure on the brake pedal, tighten the master cylinder brake
tubes.
^ Tighten to 18 Nm (13 ft. lbs.).
Brake Caliper Bleeding
NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened
part of the system.
1. Connect one end of a clear flexible hose to the bleeder screw. Submerge the other end in a
container partially filled with clean, specified brake
fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Open the caliper bleeder screw until brake fluid flows into the container. 4. When fluid stops
flowing, close the bleeder screw.
^ Tighten to 10 Nm (89 inch lbs.) for the front brake bleeder screw and 22 Nm (16 ft. lbs.) for the
rear brake bleeder screw.
5. Repeat the previous 3 steps until there are no air bubbles in the brake fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake System
Bleeding > Page 1462
Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU)
Bleeding
Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is
required only when a new HCU is installed.
1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure
to bleed the system. Begin at the RH rear caliper.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Special Tool(s)
Special Tool(s)
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box
(SJB), located below the LH side of the instrument panel, remove the cover and the restraints
control module (RCM)
fuse 17 (10A) from the SJB.
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 switch to OFF.
6. WARNING: To avoid accidental deployment and possible personal 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
servicing, 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.
The front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1467
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.
2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the
cover.
4. 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.
5. Prove out the SRS as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1468
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment, which can result in personal injury.
- The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always
wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never
probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in
pretensioner, adaptive load limiting retractor or air bag deployment and could 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 reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1469
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart
junction box (SJB), located below the LH side of the instrument panel, remove the cover and the
restraints control module (RCM)
fuse 17 (10A) from the SJB.
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 front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
7. Remove the 2 driver air bag module bolts (1 shown).
8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation.
Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1470
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
10. Open and lower the glove compartment door.
11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield.
12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive
tether squibs do not require deactivation.
Through the glove compartment opening, disconnect the LH side passenger air bag module
electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector on the LH side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1471
14. From under the rear of the passenger seat, detach the passenger seat side air bag module
electrical connector from the seat track bracket. Then
slide and disengage the passenger seat side air bag module electrical connector locking clip, and
then release the tab and disconnect the passenger seat side air bag module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Vehicles without safety canopy modules
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM.
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Explorer and Mountaineer vehicles with safety canopy modules
17. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1472
18. Disconnect the passenger side safety canopy module electrical connector.
19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
20. Release and position aside the driver side C-pillar trim panel.
21. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Supplemental Restraint System (SRS) Depowering and Repowering > Page 1473
22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles with safety canopy modules
23. Remove the driver and passenger side upper C-pillar trim panels.
24. Disconnect the passenger side safety canopy module electrical connector.
25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
26. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1474
27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles
28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module
electrical connector locking clip, and then release
the tab and disconnect the driver seat side air bag module electrical connector.
29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the
battery ground cable.
Reactivation
All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side
air bag module electrical connector.
4. Connect the driver seat side air bag module electrical connector and then slide and engage the
seat side air bag electrical connector locking clip.
Explorer Sport Trac vehicles with safety canopy modules
5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
6. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Supplemental Restraint System (SRS) Depowering and Repowering > Page 1476
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy module electrical connector.
8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and
passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles with safety canopy modules
10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
11. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
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12. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
side safety canopy module electrical connector.
14. Connect the passenger side safety canopy module electrical connector.
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
seat side air bag module electrical connector.
17. Connect the passenger seat side air bag module electrical connector and then slide and
engage the seat side air bag electrical connector locking
clip. Then attach the passenger seat side air bag module electrical connector to the seat track
bracket.
18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector on the LH side.
19. Connect the LH side passenger air bag module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21.
Close glove compartment door.
22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the
driver air bag module in the wrong
position. Match the electrical connector key to the keyway in the driver air bag module. Do not force
the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted in removal.
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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25. 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.
26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and
install the cover.
28. 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.
29. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch back to ON and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a
scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1486
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1487
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1488
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1489
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1490
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1491
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1492
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1493
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1494
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1495
Fuse: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Diagram Information and Instructions > Page 1498
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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Diagram Information and Instructions > Page 1499
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Diagram Information and Instructions > Page 1501
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Symbols Part 2
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Diagram Information and Instructions > Page 1503
Symbols Part 3
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Diagram Information and Instructions > Page 1504
Symbols Part 4
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Diagram Information and Instructions > Page 1505
Symbols Part 5
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Diagram Information and Instructions > Page 1506
Fuse: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Diagram Information and Instructions > Page 1508
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Diagram Information and Instructions > Page 1509
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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Diagram Information and Instructions > Page 1510
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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Diagram Information and Instructions > Page 1511
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
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Diagram Information and Instructions > Page 1514
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1517
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1518
Fuse
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1519
Fuse
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1520
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1521
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1522
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1523
Fuse
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1524
Fuse
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ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1525
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1526
Fuse: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1531
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1532
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1533
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1534
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1535
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1536
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1537
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1538
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1539
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1540
Fuse Block: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1543
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1544
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1545
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1546
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1547
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1548
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1549
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1550
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1551
Fuse Block: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1552
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1553
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1554
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1555
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1556
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1557
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1558
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1559
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1560
Fuse Block: Connector Views
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1561
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1562
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1563
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1564
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1565
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1568
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1569
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1570
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1571
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1572
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1573
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1574
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1575
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1576
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1577
Fuse Block: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1582
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1583
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1584
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1585
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1586
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1587
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1588
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1589
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1590
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1591
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1594
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1595
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1596
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1597
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Battery Junction Box (BJB) > Page 1598
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1601
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1602
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1603
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1604
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1605
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1606
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1607
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1608
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1609
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Information > Testing and Inspection
Low Tire Pressure Indicator: Testing and Inspection
TPMS Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that
cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced.
TPMS Indicator Illuminates Continuously
NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the
vehicle to restore complete TPMS functionality before carrying out any diagnosis.
1. The TPMS indicator remains on continuously for this condition:
^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays
LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low.
When this condition exists, the tire pressure must be adjusted to the recommended cold pressure
as indicated on the vehicle certification label.
2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been
stationary for more than 30 minutes, it will be
necessary to wake up the sensors so they will transmit the latest tire pressure information to the
SJB.
If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the
TPMS sensors. 1
Turn the ignition switch to the ON position.
2 Adjust the air pressure in the LF tire.
3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool.
4 Repeat Steps 2 and 3 for the remaining tires.
5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to
Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom
Related Diagnostic Procedures
TPMS Indicator Flashes
The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is
turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the
message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning.
GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Symptom Related Diagnostic Procedures
2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is
illuminated when the instrument cluster has received no
signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
MONITOR FAULT. GO to Symptom Chart. See: Wheels and Tires/Tire Monitoring System/Testing
and Inspection/Symptom Related Diagnostic Procedures
3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR
FAULT when the tire pressure monitoring system is
malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart.
See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related
Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 MIL notifies the driver that the powertrain control module (PCM) has detected an on board
diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD
diagnostic trouble code (DTC) sets.
- The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or the international standards organization (ISO) standard engine symbol.
- The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
- The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists.
- the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
- the PCM is operating in the hardware limited operation strategy (HLOS).
- The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster
concern is present.
- To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3
consecutive drive cycles must be completed without a concern.
- For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures
- If the MIL flashes at a steady rate, a severe misfire condition may exist.
- If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low.
- The MIL flashes after a period of time with the key in the RUN position (engine not running) if
DTC P1000 is set.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
Message Center Configuration Oil Life Reset - Message Center Cluster
NOTE:The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days
1. Press and release the SETUP button until the message center displays PRESS RESET TO
BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center
displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and
release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET.
Oil Life Reset - Base Instrument Cluster
NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days.
1. Place the ignition in the RUN position with the engine off (KOEO). 2. Press and release the
TRIP/RESET button until SETUP MENU HOLD RESET is displayed. 3. Press and hold the
TRIP/RESET button until SYSTEM CHECK is displayed. 4. Release the TRIP/RESET button. 5.
Press and release the TRIP/RESET button to scroll through the system check menu items until
HOLD RESET IF NEW OIL is displayed. 6. Press and hold the TRIP/RESET button until OIL LIFE
SET TO 100% is displayed. 7. Release the TRIP/RESET button. The oil life is now reset.
Oil Life Start Value - Message Center Cluster
NOTE:The oil life start value is used to reset the oil life value back to the maximum of
approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value
from the maximum (8,000 km
To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000
km) or 180 days] perform the following:
1. Enter SYSTEM CHECK to display "OIL XXX% OIL LIFE OK". 2. Press RESET control to display
"HOLD RESET IF NEW OIL". 3. Press and hold RESET control for more than 2 seconds. Oil life is
set to 100% and "OIL CHANGE SET TO 100%" is displayed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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.
CAUTION:
- A wheel chock should be used to prevent the vehicle from rolling and falling off the jack.
- Position the jack to avoid contact with the fuel tank.
The following offers general guidelines for vehicle jacking. Additionally, jack manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
jacking equipment before use.
Jacking Points
NOTE: Place a wheel chock diagonally opposite of the wheel to be raised.
The front jacking points are indicated by a cut-out in the frame, located behind the front tire and
wheel.
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle
cover and adjoining differential housing
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 1624
surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point
where the cover joins the housing.
The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel.
LIFTING
Lifting Points
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
- Position the hoist adapters to avoid contact with the fuel tank.
- To avoid damage to the suspension, do not position the hoist adapters on the rear trailing arm
brackets.
NOTE: Explorer shown, Explorer Sport Trac similar.
The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
lifting equipment before use. Position the hoist directly under the frame rails.
Position the hoist directly under the frame rails.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Testing and Inspection
Tire Pressure Sensor: Testing and Inspection
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Smart Junction Box (SJB).
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Testing and Inspection > Page 1629
6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees)
from the valve stem. Press and release the test
button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the
tire pressure sensor has been recognized by the SJB.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and
the entire procedure must be repeated.
8. Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will be
verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and
document them on the applicable warranty claim.
NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed SJB.
10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry
out the SJB On-Demand Self Test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor can be removed and installed without removing the strap or the cradle.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Dismount the tire only as
instructed.
Remove the tire from the wheel.
2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor locking clip can occur.
Using a pocket screwdriver, or similar tool, remove the sensor locking clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1632
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor can occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle.
4. Remove the sensor.
Assembly
1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor
installation.
NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise
when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the
cradle and pushing the opposite end of the sensor down onto the cradle.
2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the
sensor locking clip cannot be fully inserted, then
the sensor may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1633
3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1634
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1635
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There
are several different strap kits available based on wheel diameter but all strap kits share the same
base part number.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. Remove the tire pressure monitoring system (TPMS) sensor.
2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and
gloves when removing the TPMS
band/strap. Failure to follow these instructions may result in personal injury.
Remove a factory installed strap in this sequence: 1
Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both
sides of the buckle approximately 25 mm (0.98 inch) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is
fully released from the worm gear.
^ Discard the strap.
3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle
and prying up.
Assembly
1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click"
noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of the sensor down onto the cradle.
2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to
remove the cradle adhesive strip residue.
NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the
valve stem.
Clean the area where the sensor and cradle are to be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1636
3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH
side when viewed from the curb side (beauty side)
of the wheel.
NOTE: The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel
drop well 180° from the valve stem.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is
positioned in the lowest spot possible for
correct sensor and cradle retention.
NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm
gear. ^
Tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1637
6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
Component Information > Testing and Inspection
Low Tire Pressure Indicator: Testing and Inspection
TPMS Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that
cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced.
TPMS Indicator Illuminates Continuously
NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the
vehicle to restore complete TPMS functionality before carrying out any diagnosis.
1. The TPMS indicator remains on continuously for this condition:
^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays
LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low.
When this condition exists, the tire pressure must be adjusted to the recommended cold pressure
as indicated on the vehicle certification label.
2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been
stationary for more than 30 minutes, it will be
necessary to wake up the sensors so they will transmit the latest tire pressure information to the
SJB.
If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the
TPMS sensors. 1
Turn the ignition switch to the ON position.
2 Adjust the air pressure in the LF tire.
3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool.
4 Repeat Steps 2 and 3 for the remaining tires.
5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to
Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures
TPMS Indicator Flashes
The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is
turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the
message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning.
GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures
2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is
illuminated when the instrument cluster has received no
signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related
Diagnostic Procedures
3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR
FAULT when the tire pressure monitoring system is
malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart.
See: Testing and Inspection/Symptom Related Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Testing and Inspection
Tire Pressure Sensor: Testing and Inspection
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Smart Junction Box (SJB).
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Testing and Inspection > Page 1645
6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees)
from the valve stem. Press and release the test
button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the
tire pressure sensor has been recognized by the SJB.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and
the entire procedure must be repeated.
8. Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will be
verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and
document them on the applicable warranty claim.
NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed SJB.
10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry
out the SJB On-Demand Self Test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor can be removed and installed without removing the strap or the cradle.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Dismount the tire only as
instructed.
Remove the tire from the wheel.
2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor locking clip can occur.
Using a pocket screwdriver, or similar tool, remove the sensor locking clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1648
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor can occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle.
4. Remove the sensor.
Assembly
1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor
installation.
NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise
when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the
cradle and pushing the opposite end of the sensor down onto the cradle.
2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the
sensor locking clip cannot be fully inserted, then
the sensor may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1649
3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1650
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1651
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There
are several different strap kits available based on wheel diameter but all strap kits share the same
base part number.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. Remove the tire pressure monitoring system (TPMS) sensor.
2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and
gloves when removing the TPMS
band/strap. Failure to follow these instructions may result in personal injury.
Remove a factory installed strap in this sequence: 1
Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both
sides of the buckle approximately 25 mm (0.98 inch) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is
fully released from the worm gear.
^ Discard the strap.
3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle
and prying up.
Assembly
1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click"
noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of the sensor down onto the cradle.
2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to
remove the cradle adhesive strip residue.
NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the
valve stem.
Clean the area where the sensor and cradle are to be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1652
3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH
side when viewed from the curb side (beauty side)
of the wheel.
NOTE: The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel
drop well 180° from the valve stem.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is
positioned in the lowest spot possible for
correct sensor and cradle retention.
NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm
gear. ^
Tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 1653
6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 1662
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 1663
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns >
Page 1664
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 1670
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 1671
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 1672
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking
Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking >
Page 1681
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
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds
Wheels: Customer Interest Wheels/Tires - Popping/Snapping Noise At Low Speeds
TSB 09-11-2
06/15/09
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEED BELOW 10 MPH (16 KM/H)
FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer
LINCOLN: 2007-2008 MKX
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 09-4-3 to update the vehicle model years.
ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008
and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels
may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at
speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that
attaches to the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual
(WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds >
Page 1686
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft(R) Silicone Spray
Lubricant with an extension nozzle. (Figures 1 and 2)
4. Clean any excess lubricant off the wheel with a soft cloth.
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
091102A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace One Wheel
and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091102B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace Two
Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091102C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds >
Page 1687
MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire
Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
091102D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive,
Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When
Turning
Wheels: Customer Interest Wheels/Tires - Popping Noise From Wheels When Turning
TSB 07-23-4
11/26/07
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEEDS BELOW 10 MPH (16KM/H)
FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 07-19-6 to update the vehicle lines.
ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to
8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may
exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds
lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to
the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel
and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When
Turning > Page 1692
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension
nozzle. (Figures 1 and 2)
NOTE
NEW WHEELS WILL NOT REQUIRE LUBRICATION.
4. Clean any excess lubricate off the wheel with a soft cloth.
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
072304A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining
Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance
Wheel Assembly (Do Not Use With 1007A, 1007A1)
072304B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two
Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
072304C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When
Turning > Page 1693
Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS,
Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
072304D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking
Wheels: Customer Interest Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking
TSB 07-12-2
06/25/07
16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch
wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like
spider webs.
ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection.
SERVICE PROCEDURE
Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to
Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of
affected wheel in Figure 1.
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
071202A 2006-2007 Explorer, 2007 0.5 Hr.
Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking >
Page 1698
071202B 2006-2007 Explorer, 2007 0.7 Hr.
Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202C 2006-2007 Explorer, 2007 1.0 Hr.
Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202D 2006-2007 Explorer, 2007 1.2 Hrs.
Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat
Cracking
Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat
Cracking > Page 1704
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
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At
Low Speeds
Wheels: All Technical Service Bulletins Wheels/Tires - Popping/Snapping Noise At Low Speeds
TSB 09-11-2
06/15/09
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEED BELOW 10 MPH (16 KM/H)
FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer
LINCOLN: 2007-2008 MKX
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 09-4-3 to update the vehicle model years.
ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008
and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels
may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at
speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that
attaches to the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual
(WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At
Low Speeds > Page 1709
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft(R) Silicone Spray
Lubricant with an extension nozzle. (Figures 1 and 2)
4. Clean any excess lubricant off the wheel with a soft cloth.
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
091102A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace One Wheel
and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091102B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace Two
Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091102C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At
Low Speeds > Page 1710
MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire
Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
091102D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive,
Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels
When Turning
Wheels: All Technical Service Bulletins Wheels/Tires - Popping Noise From Wheels When Turning
TSB 07-23-4
11/26/07
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEEDS BELOW 10 MPH (16KM/H)
FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 07-19-6 to update the vehicle lines.
ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to
8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may
exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds
lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to
the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel
and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels
When Turning > Page 1715
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension
nozzle. (Figures 1 and 2)
NOTE
NEW WHEELS WILL NOT REQUIRE LUBRICATION.
4. Clean any excess lubricate off the wheel with a soft cloth.
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
072304A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining
Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance
Wheel Assembly (Do Not Use With 1007A, 1007A1)
072304B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two
Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
072304C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels
When Turning > Page 1716
Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS,
Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
072304D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking
Wheels: All Technical Service Bulletins Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking
TSB 07-12-2
06/25/07
16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch
wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like
spider webs.
ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection.
SERVICE PROCEDURE
Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to
Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of
affected wheel in Figure 1.
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
071202A 2006-2007 Explorer, 2007 0.5 Hr.
Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking > Page 1721
071202B 2006-2007 Explorer, 2007 0.7 Hr.
Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202C 2006-2007 Explorer, 2007 1.0 Hr.
Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202D 2006-2007 Explorer, 2007 1.2 Hrs.
Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove and discard the halfshaft nut and washer.
^ To install, tighten to 250 Nm (184 ft. lbs.)
3. Using the special tool, separate the outboard CV joint from the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1726
4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^
Discard the bolts.
^ Support the caliper and anchor plate assembly using mechanic's wire.
^ To install, tighten to 165 Nm (122 ft. lbs.)
5. Remove the brake disc.
6. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it
from the wheel bearing and hub.
Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel
bearing and hub assembly. ^
To install, tighten to 18 Nm (13 ft. lbs.)
7. Remove the 3 bolts and the wheel bearing and hub assembly.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 ft. lbs.)
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1727
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts.
^ To install, tighten to 8 Nm (71 inch lbs.)
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front > Page 1728
4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To
install, reverse the removal procedure. 7. Install the wheel knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Axle Nut ...............................................................................................................................................
................................................ 250 Nm (184 ft. lbs.)
Remove and discard the halfshaft nut and washer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
Wheel Lug Nuts
..........................................................................................................................................................
135 Nm (100 ft. lbs.) in a star pattern
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
Wheel Studs
Special Tool(s)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^
Support the caliper and anchor plate assembly using mechanic's wire.
^ To install, tighten to 200 Nm (148 ft. lbs.)
3. Remove the brake disc. 4. Using the special tool, remove the wheel stud.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1738
Installation
1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be
stripped.
NOTE: Do not use the wheel nut that came with the vehicle.
Install washers and a new wheel nut on the wheel stud and tighten the nut until the stud seats
against the flange. ^
Discard the wheel nut and washers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1739
Wheel Fastener: Service and Repair Rear
Wheel Studs
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1740
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in when removed.
1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. CAUTION: Care must be used when servicing rear brake components without disconnecting the
parking brake cable from the brake
caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking
brake cable end fittings can occur.
CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the brake caliper aside. ^
Support the caliper using mechanic's wire.
3. Remove the brake disc.
4. Remove the parking brake shoe adjuster spring and adjuster.
5. CAUTION: The brake shield has an access hole knockout that must be removed to allow for the
removal of the wheel stud.
Using a suitable punch, remove the access hole cover from the brake shield.
6. NOTE: Make sure that the wheel stud is aligned with the recessed area of the wheel knuckle.
Using the special tool, press the wheel stud until it makes contact with the edge of the wheel
knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1741
7. Route the wheel stud through the access hole and discard the wheel stud.
Installation
1. Position the new wheel stud aligning the serrations in the wheel hub made by the original wheel
stud.
2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be
stripped.
NOTE: Do not use the wheel nut that came with the vehicle.
Place flat washers over the outside end of the wheel stud and thread a standard wheel nut with the
flat side against the washers. Tighten the wheel nut until the wheel stud seats against the back side
of the wheel extension. ^
Discard the wheel nut and washers.
3. CAUTION: A plug must be installed in place of the knockout to prevent contamination to the
parking brake shoe assemblies.
Install a plug into the access hole on the brake shield.
4. Install the parking brake shoe adjuster and spring. 5. Install the brake disc. 6. Position the brake
caliper and install the bolts.
^ Tighten to 32 Nm (24 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle
- Tow Capability/Service Kit Requirements
Towing Information: Technical Service Bulletins Vehicle - Tow Capability/Service Kit Requirements
TSB 06-7-1
04/17/06
NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS
FORD: 2004-2006 Focus 2004 F-150 Heritage 2004-2005 Explorer Sport Trac 2004-2006 Escape,
Explorer, F-150-350 Series, Ranger 2005-2006 Escape Hybrid 2007 Explorer Sport Trac
LINCOLN: 2006 Mark LT
MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 06-4-5 to update the vehicle neutral tow application chart.
ISSUE Various vehicles are neutral tow capable. Refer to the following chart to determine neutral
tow capability for specific vehicle applications, and to determine if a Service Kit is required to make
the vehicle neutral tow capable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle
- Tow Capability/Service Kit Requirements > Page 1746
ACTION Review the neutral tow application chart (Figure 1) and order the kit, if applicable.
Reprogramming of various modules may be required for some installations. Installation instructions
are included with the kit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle
- Tow Capability/Service Kit Requirements > Page 1747
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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.
CAUTION:
- A wheel chock should be used to prevent the vehicle from rolling and falling off the jack.
- Position the jack to avoid contact with the fuel tank.
The following offers general guidelines for vehicle jacking. Additionally, jack manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
jacking equipment before use.
Jacking Points
NOTE: Place a wheel chock diagonally opposite of the wheel to be raised.
The front jacking points are indicated by a cut-out in the frame, located behind the front tire and
wheel.
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle
cover and adjoining differential housing
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
1751
surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point
where the cover joins the housing.
The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel.
LIFTING
Lifting Points
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
- Position the hoist adapters to avoid contact with the fuel tank.
- To avoid damage to the suspension, do not position the hoist adapters on the rear trailing arm
brackets.
NOTE: Explorer shown, Explorer Sport Trac similar.
The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
lifting equipment before use. Position the hoist directly under the frame rails.
Position the hoist directly under the frame rails.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
C1451
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 1759
C1452
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 1760
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAMSHAFT TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake phase shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default
mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM)
determines the phase angle based on air flow, engine oil temperature and engine coolant
temperature. At part and wide open throttle the PCM determines the phase angle based on engine
RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine
power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque.
In addition, some VCT system applications can eliminate the need for an external exhaust gas
recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the
overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS
and DEPS systems are used.
Variable Camshaft Timing (VCT) System
VCT System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments. 1. The PCM receives input signals from the intake air temperature (IAT)
sensor, engine coolant temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system does not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It continually updates the VCT
solenoid duty cycle until the desired position is achieved. A difference between the desired and
actual camshaft position represents a position error in the PCM VCT control loop. The PCM
disables the VCT and places the camshaft in a default position if a concern is detected. A related
DTC is also set when the concern is detected.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 1761
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the camshaft timing.
One half of the VCT actuator is coupled to the camshaft and the other half is connected to the
timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When
the flow of oil is shifted from one side of the chamber to the other, the differential change in oil
pressure forces the camshaft to rotate in either an advance or retard position depending on the oil
flow.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Service and Repair
Variable Valve Timing Solenoid: Service and Repair
VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID
Removal and Installation
1. Remove the valve cover. 2. Remove the bolt and the VCT oil control solenoid.
- To install, tighten to 5 Nm (44 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1768
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 5 compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
If one or more cylinders read 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 2 adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may be
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1769
leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is at least 75% of the highest reading.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 LH
Tighten to .............................................................................................................................................
........................................... 10 Nm (89 inch lbs.).
Camshaft Bearing cap bolts RH
Tighten to .............................................................................................................................................
........................................... 10 Nm (89 inch lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Service and Repair
Camshaft Gear/Sprocket: Service and Repair
Special Tool(s)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional
information, refer to Camshaft - RH. See:
Camshaft/Service and Repair
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional
information, refer to Camshaft - LH. See:
Camshaft/Service and Repair
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
- If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
- If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Service and Repair > Page 1777
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Installation
1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to
valves and pistons will result.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional
information, refer to Camshaft - RH. See:
Camshaft/Service and Repair
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional
information, refer to Camshaft - LH. See:
Camshaft/Service and Repair
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures
Camshaft: Service and Repair General Procedures
Camshaft Bearing Journal Diameter
Camshaft Bearing Journal Diameter
1. Measure each camshaft journal diameter in 2 directions.
^ If out of specification, install new components as necessary.
Camshaft Bearing Journal Clearance
Camshaft Bearing Journal Clearance
NOTE: The camshaft journals must meet specifications before checking camshaft journal
clearance.
1. Remove the camshaft bearing cap and lay Plastigage across the surface.
2. NOTE: Do not turn the camshaft while carrying out this procedure.
Position the camshaft bearing cap and install the bolts.
3. Use Plastigage to verify the camshaft journal clearance.
^ If out of specification, install new components as necessary.
Camshaft End Play
Camshaft End Play
Special Tools
1. Remove the roller followers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1782
2. Use the special tool to measure camshaft end play. 3. Position the camshaft to the rear of the
cylinder head. 4. Zero the indicator. 5. Move the camshaft to the front of the cylinder head. Note
and record the camshaft end play.
^ If camshaft end play exceeds specifications, install new camshaft and recheck end play.
^ If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.
Camshaft Surface Inspection
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable
outside the contact area.
^ If excessive pitting or damage is present, install new components as necessary.
Camshaft Lobe Lift
Camshaft Lobe Lift
Special Tools
1. Use the special tool to measure camshaft intake/exhaust lobe lift.
^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading
to figure the camshaft lobe lift.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1783
Camshaft Runout
Camshaft Runout
Special Tool(s)
1. NOTE: Camshaft journals must be within specifications before checking runout.
Use the special tool to measure the camshaft runout. ^
Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1784
Camshaft: Service and Repair Camshaft - LH
Special Tool(s)
Material
Removal
NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons
will result.
1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation
at the 1 o'clock position.
2. Remove the LH valve cover.
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1785
4. Disconnect the LH camshaft position (CMP) sensor electrical connector.
5. Remove the LH CMP sensor and the bolt.
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will
require one full additional rotation to 12 o'clock.
The No.5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the
position of the 2 intake camshaft lobes and the exhaust lobe on the No.5 cylinder.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1786
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTICE: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure to follow
these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If
a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove only the 3 designated camshaft roller followers from the previous
step.
9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine
damage may occur.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1787
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke
at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage
to valves and pistons will result.
NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine
block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the LH timing chain as shown.
11. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
NOTE: RH shown, LH similar.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1788
Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged from side
loading.
Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.
Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft
bearing caps.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1789
14. Clean and inspect the LH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly,
leaving the camshaft phaser and sprocket assembly in place.
Discard the bolt and washer.
16. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to
Camshaft Phaser and Sprocket. See: In-Vehicle Repair
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1790
Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a
new camshaft phaser and sprocket bolt finger-tight.
3. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
NOTE: RH shown, LH similar.
Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap.
- Position the remaining camshaft bearing caps.
- Install the bolts loosely.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1791
5. Tighten the bolts in the sequence shown. Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity.
Remove the special tools.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1792
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at
the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No.5 cylinder intake and exhaust
camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed. For additional information, refer to Cylinder Head. See: Cylinder
Head Assembly
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1793
11. Connect the CMP electrical connector.
12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage
may occur to the camshaft or camshaft phaser and
sprocket.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Tighten the camshaft phaser and sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90°.
13. In stall the LH valve cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1794
Camshaft: Service and Repair Camshaft - RH
Special Tool(s)
Material
Removal
NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons
will result.
1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation
at the 1 o'clock position.
2. Remove the RH valve cover.
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
Loosen and back off the RH camshaft phaser and sprocket bolt one full turn.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1795
4. Disconnect the RH camshaft position (CMP) sensor electrical connector.
5. Remove the bolt and the RH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one
full additional rotation to 12 o'clock.
The No.1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by
noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No.1 cylinder.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1796
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTICE: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure to follow
these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If
a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the special tool, remove only the 3 designated camshaft roller followers from the previous
step.
9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke
at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1797
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage
to valves and pistons will result.
NOTE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine
block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the RH timing chain as shown.
11. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components.
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged from side
loading.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1798
Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
13. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.
Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft
bearing caps.
14. Clean and inspect the RH camshaft bearing caps.
- The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is
free of foreign material.
15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1799
Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly,
leaving the camshaft phaser and sprocket assembly in place. Discard the bolt and washer.
16. Inspect the camshaft phaser and sprocket for damage. For additional information, refer to
Camshaft Phaser and Sprocket. See: Camshaft
Gear/Sprocket
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil.
2. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a
new camshaft phaser and sprocket bolt finger-tight.
3. NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the
special tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components. See: Timing Components
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to valves and pistons will result.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1800
Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the
camshaft.
Install the camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap.
- Position the remaining camshaft bearing caps.
- Install the bolts loosely.
5. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1801
Remove the special tool.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at
the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No.1 cylinder intake and exhaust
camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the
cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1802
Using the special tool, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
11. Connect the CMP electrical connector.
12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage
may occur to the camshaft or camshaft phaser and
sprocket.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Tighten the new camshaft phaser and sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1803
- stage 2: Tighten an additional 90°.
13. Install the RH valve cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1804
Camshaft: Service and Repair In-Vehicle Repair
Special Tool(s)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional
information, refer to Camshaft - RH. See:
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional
information, refer to Camshaft - LH. See:
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See: Timing
Components
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
- If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
- If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > General Procedures > Page 1805
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Installation
1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to
valves and pistons will result.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional
information, refer to Camshaft - RH. See:
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional
information, refer to Camshaft - LH. See:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Testing and Inspection
Lifter / Lash Adjuster: Testing and Inspection
Valve Tappet Inspection
Push rod engines
1. Inspect the hydraulic valve tappet and roller for damage. If any damage is found, inspect the
camshaft lobes and valves for damage.
OHC engines
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Testing and Inspection > Page 1809
Lifter / Lash Adjuster: Service and Repair
Hydraulic Lash Adjuster
Material
Removal and Installation
1. Remove the camshafts. 2. Remove the remaining roller followers from the cylinder head being
serviced.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
Remove the hydraulic lash adjusters that are being serviced.
4. Inspect the hydraulic lash adjusters.
5. NOTE: Lubricate each of the hydraulic lash adjusters with clean engine oil prior to installation.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Camshaft Roller Follower
Special Tools
Material
Removal
1. Depending on the roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the
crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve
and the exhaust valves closed.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower.
Installation
1. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
NOTE: Lubricate the roller follower with clean engine oil.
Using the special tool, compress the valve spring and install the camshaft roller follower.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair > Page 1813
2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve
being serviced, install the LH or RH valve cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
C1451
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 1818
C1452
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 1819
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAMSHAFT TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake phase shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default
mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM)
determines the phase angle based on air flow, engine oil temperature and engine coolant
temperature. At part and wide open throttle the PCM determines the phase angle based on engine
RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine
power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque.
In addition, some VCT system applications can eliminate the need for an external exhaust gas
recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the
overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS
and DEPS systems are used.
Variable Camshaft Timing (VCT) System
VCT System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments. 1. The PCM receives input signals from the intake air temperature (IAT)
sensor, engine coolant temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system does not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It continually updates the VCT
solenoid duty cycle until the desired position is achieved. A difference between the desired and
actual camshaft position represents a position error in the PCM VCT control loop. The PCM
disables the VCT and places the camshaft in a default position if a concern is detected. A related
DTC is also set when the concern is detected.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Diagrams > Page 1820
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the camshaft timing.
One half of the VCT actuator is coupled to the camshaft and the other half is connected to the
timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When
the flow of oil is shifted from one side of the chamber to the other, the differential change in oil
pressure forces the camshaft to rotate in either an advance or retard position depending on the oil
flow.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
Connecting rod bearing-to-crankshaft clearance
....................................................................................................... 0.024-0.066 mm (0.0009-0.0026
inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications
Connecting Rod: Specifications
Connecting rod-to-pin clearance
............................................................................................................................... 0.009-0.023 mm
(0.0004-0.0009 inch) Connecting rod pin bore diameter
......................................................................................................................... 22.012-22.024 mm
(0.8666-0.8671 inch) Connecting rod length (center-to-center)
........................................................................................................................................... 150.7 mm
(5.933 inch) Connecting rod maximum allowed bend
......................................................................................................................................... 0.038 mm
(0.0015 inch) Connecting rod maximum allowed twist a
......................................................................................................................................... 0.05 mm
(0.0020 inch) Connecting rod bearing bore diameter (with assembled liners)
............................................................................ 53.049-53.027 mm (2.0885-2.0877 inch)
Connecting rod side clearance
............................................................................................................................................... 0.5-0.15
mm (0.02-0.006 inch)
a The pin bore and crank bearing bore must be parallel and in the same vertical plane within the
specified total difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of
rod centerline.
Connecting Rod Bolts
Stage 1: Tighten to ..............................................................................................................................
................................................ 43 Nm (32 ft. lbs.). Stage 2: Tighten an ..............................................
......................................................................................................................... additional 105
degrees.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 1828
Connecting Rod: Testing and Inspection
Bearing Inspection
1. Inspect bearings for the following defects. Possible causes are shown:
1 Cratering - fatigue failure.
2 Spot polishing - incorrect seating.
3 Imbedded dirt engine oil.
4 Scratching - dirty engine oil.
5 Base exposed - poor lubrication.
6 Both edges worn - journal damaged.
7 One edge worn - journal tapered or bearing not seated.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance
Connecting Rod: Service and Repair Connecting Rod Bearing Journal-to-Bearing Clearance
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing
surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates
a tapered or damaged connecting rod or connecting rod bearing. ^
If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1831
Connecting Rod: Service and Repair Connecting Rod Bend
Connecting Rod Bend
1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the bend measurement
is within specification. ^
If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1832
Connecting Rod: Service and Repair Connecting Rod Bushing Diameter
Connecting Rod Bushing Diameter
1. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if
equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1833
Connecting Rod: Service and Repair Connecting Rod Cleaning
Connecting Rod Cleaning
CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed
on the original connecting rod in the original
position. Do not reverse the cap. Parts are not interchangeable.
Mark and separate the parts and clean with solvent. Clean the oil passages.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1834
Connecting Rod: Service and Repair
Connecting Rod Bearing Journal-to-Bearing Clearance
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap. 2. Position a piece of Plastigage across the bearing
surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates
a tapered or damaged connecting rod or connecting rod bearing. ^
If out of specification, install new components as necessary.
Connecting Rod Bend
Connecting Rod Bend
1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the bend measurement
is within specification. ^
If out of specification, install new components as necessary.
Connecting Rod Bushing Diameter
Connecting Rod Bushing Diameter
1. Use a telescoping gauge to determine the inner diameter of the connecting rod bushing, if
equipped.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1835
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
^ If out of specification, install new components as necessary.
Connecting Rod Cleaning
Connecting Rod Cleaning
CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed
on the original connecting rod in the original
position. Do not reverse the cap. Parts are not interchangeable.
Mark and separate the parts and clean with solvent. Clean the oil passages.
Connecting Rod Large End Bore
Connecting Rod Large End Bore
1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the
connecting rod bore out-of-round. Verify the
out-of-round is within specification. ^
If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Service and Repair > Connecting Rod Bearing Journal-to-Bearing Clearance > Page 1836
Connecting Rod Twist
Connecting Rod Twist
1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the
fixture manufacturer. Verify the measurement is
within specification. ^
If out of specification, install new components as necessary.
Piston Wrist Pin Side Clearance
Piston Wrist Pin Side Clearance
1. Measure the clearance between the connecting rod and the piston. Verify the measurement is
within specification.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications
Crankshaft Main Bearing: Specifications
Main bearing journal-to-cylinder block clearance
..................................................................................................... 0.048-0.024 mm (0.0019-0.0009
inch)
Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages.
Stage 1: Tighten to ..............................................................................................................................
................................................ 40 Nm (30 ft. lbs.). Stage 2: Tighten an ..............................................
........................................................................................................................... additional 90
degrees.
Tighten the jackscrews against the cylinder block in the sequence shown in 2 stages.
Stage 1: Tighten to ..............................................................................................................................
.............................................. 5 Nm (44 inch lbs.). Stage 2: Tighten to ...............................................
........................................................................................................................... 10 Nm (89 inch lbs.).
Install the side bolts and tighten them in the sequence shown.
Tighten to .............................................................................................................................................
.............................................. 21 Nm (15 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 1840
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 1841
Crankshaft Main Bearing: Testing and Inspection
Bearing Inspection
1. Inspect bearings for the following defects. Possible causes are shown:
1 Cratering - fatigue failure.
2 Spot polishing - incorrect seating.
3 Imbedded dirt engine oil.
4 Scratching - dirty engine oil.
5 Base exposed - poor lubrication.
6 Both edges worn - journal damaged.
7 One edge worn - journal tapered or bearing not seated.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer >
Component Information > Service and Repair
Crankshaft Seal Retainer: Service and Repair
Crankshaft Rear Seal with Retainer Plate
Special Tools
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer >
Component Information > Service and Repair > Page 1845
Material
Removal
1. Remove the flexplate. 2. Remove the engine-to-transmission spacer plate. 3. Remove the oil
pan. 4. Using the special tools, remove the crankshaft oil slinger.
^ Discard the crankshaft oil slinger.
5. Using the special tools, remove the crankshaft rear seal.
^ Discard the crankshaft rear seal.
6. Remove the 6 bolts and the crankshaft rear seal retainer plate.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer >
Component Information > Service and Repair > Page 1846
Clean and inspect the mating surfaces.
2. NOTE: The crankshaft rear seal retaining plate does not have a sealant groove. Gasket maker
must be applied to the crankshaft rear seal retainer
plate mating surface on the engine block.
Apply a bead of gasket maker to the crankshaft rear seal retainer plate mating surface on the
engine block.
3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
4. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the special tools, install the crankshaft rear seal.
5. Using the special tools, install the crankshaft rear oil slinger.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer >
Component Information > Service and Repair > Page 1847
6. Install the oil pan. 7. Install the engine-to-transmission spacer plate. 8. Install the flexplate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Main bearing journal diameter
.............................................................................................................................. 67.481-67.505 mm
(2.6567-2.6576 inch) Main bearing journal maximum taper
.............................................................................................................................................. 0.004
mm (0.0002 inch) Main bearing journal maximum out-of-round between cross sections
........................................................................................... 0.0075 mm (0.0003 inch) Connecting rod
journal diameter ...........................................................................................................................
53.003-52.983 mm (2.0867-2.0859 inch) Connecting rod journal maximum taper
........................................................................................................................................... 0.004 mm
(0.0002 inch) Connecting rod journal maximum out-of-round between cross sections
....................................................................................... 0.0075 mm (0.0003 inch) Crankshaft
maximum end play
.................................................................................................................................. 0.075-0.377 mm
(0.0030-0.0148 inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round
Crankshaft: Service and Repair Crankshaft Main Bearing Journal Taper and Out-of-Round
Crankshaft Main Bearing Journal Taper and Out-of-Round
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each
end of the main bearing journal.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1853
Crankshaft: Service and Repair Crankshaft Main Bearing Journal-to-Bearing Clearance
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Crankshaft main bearing journals must be within specifications before checking journal
clearance.
1. Remove the crankshaft main bearing caps and crankshaft main bearing. 2. Lay a piece of
Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1854
Crankshaft: Service and Repair Crankshaft End Play
Crankshaft End Play
Special Tool(s)
1. Measure the crankshaft end play. Use the special tool to measure crankshaft end play. 2.
Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. 4. Move the
crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
^ If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft
thrust main bearing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1855
Crankshaft: Service and Repair Crankshaft Runout
Crankshaft Runout
Special Tools
1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout.
Use the special tool to measure the crankshaft runout. ^
Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator
reading to figure the crankshaft runout. If it is out of specification, install new components as
necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1856
Crankshaft: Service and Repair
Crankshaft Main Bearing Journal Taper and Out-of-Round
Crankshaft Main Bearing Journal Taper and Out-of-Round
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each
end of the main bearing journal.
^ If out of specification, install new components as necessary.
Crankshaft Main Bearing Journal-to-Bearing Clearance
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Crankshaft main bearing journals must be within specifications before checking journal
clearance.
1. Remove the crankshaft main bearing caps and crankshaft main bearing. 2. Lay a piece of
Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.
^ If out of specification, install new components as necessary.
Crankshaft End Play
Crankshaft End Play
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1857
Special Tool(s)
1. Measure the crankshaft end play. Use the special tool to measure crankshaft end play. 2.
Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. 4. Move the
crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
^ If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft
thrust main bearing.
Crankshaft Runout
Crankshaft Runout
Special Tools
1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout.
Use the special tool to measure the crankshaft runout. ^
Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator
reading to figure the crankshaft runout. If it is out of specification, install new components as
necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-of-Round > Page 1858
Crankshaft Main Bearing Journal Diameter
Crankshaft Main Bearing Journal Diameter
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.
^ If out of specification, install new components as necessary.
Connecting Rod Bearing Journal Taper and Out-of-Round
Connecting Rod Bearing Journal Taper and Out-of-Round
1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one
another at each end of the connecting rod journal.
The difference in the measurements from one end to the other is the taper. Verify measurement is
within the wear limit. ^
If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Service and Repair
Engine Block Heater: Service and Repair
Block Heater
Material
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Drain the cooling system. 3. Disconnect the block heater power
cable.
4. CAUTION: Do not loosen the block heater retaining screw more than necessary for removal.
Loosen the screw and remove the block heater. ^
To install, tighten to 3 Nm (27 inch lbs.).
5. Clean and inspect the engine block mating surface. Lubricate the block heater seal and the
cylinder block hole with clean engine coolant.
6. CAUTION: Make sure the power cable is routed and secured away from rotating or hot
components or damage to the cable can occur.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Balancer Bolt
Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
Stage 1: Tighten to ..............................................................................................................................
.......................................... 90 Nm (66 ft. lbs.). Stage 2: Loosen .........................................................
.............................................................................................................................. 360 degrees.
Stage 3: Tighten to ..............................................................................................................................
.......................................... 50 Nm (37 ft. lbs.). Stage 4: Tighten an ....................................................
............................................................................................................... additional 90 degrees.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1865
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Crankshaft Pulley
Special Tools
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the cooling fan shroud. For additional information,
refer to Cooling System. 3. Remove the accessory drive belt. 4. Remove and discard the
crankshaft pulley bolt and washer. 5. Using the special tool, remove the crankshaft pulley.
Installation
1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with metal surface prep and silicone gasket
remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to
follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1866
2. Using the special tool, install the crankshaft pulley.
3. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
4. Install the accessory drive belt. 5. Install the cooling fan shroud. For additional information, refer
to Cooling System.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston diameter - grade 1 (at right angle to pin bore) (uncoated)
.......................................................................... 90.182-90.167 mm (3.5504-3.5499 inch) Piston
diameter - grade 2 (at right angle to pin bore) (uncoated)
............................................................................ 90.196-90.179 mm (3.551-3.5503 inch) Piston
diameter - grade 3 (at right angle to pin bore) (uncoated)
............................................................................ 90.208-90.193 mm (3.5515-3.551 inch)
Piston-to-cylinder bore clearance (at grade size)
...................................................................................................... 0.017-0.047 mm (0.0007-0.0019
inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures
Piston: Procedures
Piston Inspection
Piston Inspection
Special Tool(s)
CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage
can occur.
1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If
wear marks, scores or glazing is found on the piston
skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves.
^ Make sure the oil ring holes are clean.
Piston Pin to Bore Diameter
Piston Pin to Bore Diameter
1. WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer
ring, since it has a tendency to spring
out. Wear eye protection. Failure to follow instructions may result in personal injury.
NOTE: Piston and piston pins are a matched set and should not be interchanged.
Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within
specification. ^
If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1872
Piston Diameter
Piston Diameter
1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 inch) down from
the top of the piston at the point indicated.
^ If out of specification, install new components as necessary.
Piston to Cylinder Bore Clearance
Piston To Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
Piston Selection
Piston Selection
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting
a piston.
1. Select a piston size based on the cylinder bore.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1873
2. NOTE: For precision fit, new pistons are divided into 3 categories (grade sizes). A paint spot on
the new pistons indicates the grade size. Choose
the piston with the correct paint color after measuring the cylinder bore diameter.
Choose the piston with the correct paint color.
Piston Ring End Gap
Piston Ring End Gap
CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the
cylinder bore.
CAUTION: Piston rings should not be transferred from one piston to another.
NOTE: Cylinder bore must be within specification for taper and out-of-round.
1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1874
Piston Ring-to-Groove Clearance
Piston Ring-to-Groove Clearance
1. Inspect the piston for ring land damage or accelerated wear.
2. Measure the piston ring-to-groove clearance.
^ If out of specification, install new components as necessary.
Piston Pin Diameter
Piston Pin Diameter
1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1875
Piston: Overhaul
Piston
Material
Disassembly
1. Remove the piston rings from the piston. - Discard the piston rings. 2. Remove the piston pin
retainers and the piston pin. 3. Separate the piston from the connecting rod. 4. Clean and inspect
the piston and connecting rod.
Assembly
1. NOTE: The connecting rod must be installed into the piston with identification markings toward
the front.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures > Page 1876
Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil. 3. Install the piston pin in the piston
and connecting rod assembly. 4. Install the piston pin retaining clips in the piston. 5. Lubricate the
piston and the new piston rings with clean engine oil. 6. Install the piston rings onto the piston.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Piston pin bore diameter
....................................................................................................................................
22.0125-22.0175 mm (0.8666-0.8668 inch) Piston pin diameter
............................................................................................................................................
22.0010-22.0030 mm (0.8662-0.8663 inch) Piston pin length .............................................................
..................................................................................................................... 61.8 mm (2.433 inch)
Piston pin-to-piston fit
.............................................................................................................................................
0.0095-0.023 mm (0.0004-0.0009 inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston ring end gap - top
...................................................................................................................................................
0.15-0.30 mm (0.006-0.012 inch) Piston ring end gap - intermediate
................................................................................................................................. 0.25-0.50 mm
(0.0098-0.0197 inch) Piston ring end gap - oil control
.................................................................................................................................... 0.15-0.65 mm
(0.0059-0.0256 inch) Piston ring groove width - top
....................................................................................................................................... 1.52-1.54
mm (0.0598-0.0606 inch) Piston ring groove width - intermediate
........................................................................................................................ 1.52-1.54 mm
(0.0598-0.0606 inch) Piston ring groove width - oil control
........................................................................................................................ 3.030-3.056 mm
(0.1193-0.1203 inch) Piston ring width - top and intermediate
....................................................................................................................... 1.50-1.48 mm
(0.0590-0.0582 inch) Piston ring-to-groove clearance - top
........................................................................................................................ 0.020-0.060 mm
(0.0008-0.0020 inch) Piston ring-to-groove clearance - intermediate
.......................................................................................................... 0.020-0.060 mm
(0.0008-0.0020 inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
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.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow
it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to
make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key
and wait 3 seconds to pressurize the fuel system.
Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame
scuff plate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Camshaft Roller Follower
Special Tools
Material
Removal
1. Depending on the roller follower being serviced, remove the LH or RH valve cover. 2. Rotate the
crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve
and the exhaust valves closed.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
4. Repeat the previous 2 steps for each roller follower being serviced. 5. Inspect the roller follower.
Installation
1. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
NOTE: Lubricate the roller follower with clean engine oil.
Using the special tool, compress the valve spring and install the camshaft roller follower.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair > Page 1890
2. Repeat the previous step for each roller follower being serviced. 3. Depending on the valve
being serviced, install the LH or RH valve cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH
Valve Cover: Service and Repair Valve Cover - LH
Valve Cover - LH
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1895
Removal
1. Remove the LH ignition coils. 2. Remove the bolt and position the oil level indicator and tube
aside. 3. Disconnect the evaporative emissions (EVAP) tube from the intake manifold. 4.
Disconnect the positive crankcase ventilation (PCV) hose from the valve cover. 5. Remove the nut
and position the cooling fan wiring harness bracket aside. 6. Disconnect the 2 pin-type retainers
from the valve cover. 7. Disconnect the variable camshaft timing (VCT) solenoid electrical
connector. 8. Detach the wiring harness retainers from the valve cover studs. 9. Disconnect the
EVAP canister purge valve electrical connector.
10. Disconnect the EVAP canister-to-EVAP canister purge valve EVAP hose from the EVAP
canister purge valve. 11. Loosen the 15 bolts and remove the LH valve cover and gasket.
^ Discard the gasket.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1896
Clean the gasket mating surfaces. ^
Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
^ Clean the valve cover gasket groove in the valve cover with soap and water or a suitable solvent.
2. Install a new gasket on the LH valve cover.
3. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner.
Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.
4. Position the LH valve cover with a new gasket and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
5. Connect the EVAP canister-to-EVAP canister purge valve EVAP hose to the EVAP canister
purge valve. 6. Connect the EVAP canister purge valve electrical connector. 7. Attach the wiring
harness retainers to the valve cover studs. 8. Connect the VCT solenoid electrical connector. 9.
Connect the 2 pin-type retainers to the valve cover.
10. Position the cooling fan wiring harness bracket and install the nut.
^ Tighten to 25 Nm (18 ft. lbs.).
11. Connect the PCV hose to the valve cover. 12. Connect the EVAP tube to the intake manifold.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1897
13. Position the oil level indicator tube and install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).
14. Install the LH ignition coils.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1898
Valve Cover: Service and Repair Valve Cover - RH
Valve Cover - RH
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1899
Removal
1. Remove the air cleaner and the air cleaner outlet pipe. 2. Remove the RH ignition coils.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1900
3. Disconnect the engine wiring harness from the powertrain control module.
^ Disconnect the 2 PCM electrical connectors.
^ Disconnect the in-line electrical connector.
^ Detach the wiring harness retainer from the PCM bracket and position the wiring harness aside.
4. Disconnect the RH variable camshaft timing (VCT) oil control solenoid electrical connector. 5.
Detach the 2 wiring harness retainers from the RH valve cover studs. 6. Detach the wiring harness
pin-type retainer from the front of the RH valve cover. 7. Detach the heater hose retainer from the
RH valve cover. 8. Disconnect the crankcase breather tube from the RH valve cover. 9. Loosen the
RH valve cover bolts and remove the RH valve cover and the RH valve cover gasket.
^ Discard the gasket.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Clean the gasket mating surfaces. ^
Clean the valve cover mating surface of the RH cylinder head with silicone gasket remover and
metal surface prep. Follow the directions on the packaging.
^ Clean the RH valve cover gasket groove with soap and water or a suitable solvent.
2. Install a new gasket on the RH valve cover.
3. NOTE: If the RH valve cover is not secured within 4 minutes, the sealant must be removed and
the sealing area cleaned with metal surface
cleaner. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the RH
cylinder head.
4. Position the RH valve cover with a new gasket on the cylinder head and tighten the bolts in the
sequence shown.
^ Tighten to 10 Nm (89 inch lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > Valve Cover - LH > Page 1901
5. Connect the crankcase breather tube to the RH valve cover. 6. Attach the heater hose retainer to
the RH valve cover. 7. Attach the wiring harness pin-type retainer to the front of the RH valve
cover. 8. Attach the wiring harness retainers to the RH valve cover studs. 9. Connect the RH VCT
oil control solenoid electrical connector.
10. Connect the engine wiring harness to the PCM.
^ Position the wiring harness and attach the wiring harness pin-type retainer to the PCM bracket.
^ Connect the in-line electrical connector.
^ Connect the 2 PCM electrical connectors.
11. Install the RH ignition coils. 12. Install the air cleaner and the air cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Service and Repair > Valve Guide Inner Diameter
Valve Guide: Service and Repair Valve Guide Inner Diameter
Valve Guide Inner Diameter
1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into
the combustion chamber side of the valve guide if
necessary.
Use a ball gauge to determine the inner diameter of the valve guides in 2 directions at the top,
middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, ream the valve guide and install a valve with an
oversize stem or remove the valve guide and install
a new valve guide.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Service and Repair > Valve Guide Inner Diameter > Page 1906
Valve Guide: Service and Repair Valve Guide Reaming
Valve Guide Reaming
1. Use a hand-reaming kit to ream the valve guide. 2. Reface the valve seat.
3. Clean the sharp edges left by reaming.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve Seat Inspection
Valve Seat: Service and Repair Valve Seat Inspection
Valve Seat Inspection
Valve and Seat Refacing Measurements
CAUTION: After grinding valves or valve seats, check valve clearance.
1. Check the valve head and seat.
^ Check valve angles.
^ Check margin width.
^ Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve Seat Inspection > Page 1911
Valve Seat: Service and Repair Valve Seat Width
Valve Seat Width
1. Measure the valve seat width. If necessary, grind the valve seat to specification.
^ Measure the intake valve seat width.
^ Measure the exhaust valve seat width.
^ Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve Seat Inspection > Page 1912
Valve Seat: Service and Repair Valve Seat Runout
Valve Seat Runout
1. Use a valve seat runout gauge to check valve seat runout.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Valve Spring Installed Length
Valve Spring: Service and Repair Valve Spring Installed Length
Valve Spring Installed Length
1. Measure the installed length of each valve spring.
^ If out of specification, install new components.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Valve Spring Installed Length > Page 1917
Valve Spring: Service and Repair Valve Springs
Valve Springs
Special Tools
Removal
1. Depending on the valve spring being serviced, remove the LH or RH valve cover. 2. Remove the
spark plug. 3. Rotate the crankshaft until the piston for the valve spring being serviced is at the top
of its stroke with the intake valve and the exhaust valves
closed.
4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position.
^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
6. 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.
CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into their original locations.
Using the special tool, compress the valve spring and remove the valve spring retainer keys.
7. Remove the valve spring retainer and the valve spring.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Valve Spring Installed Length > Page 1918
8. Inspect the valve spring.
Installation
1. Using the special tool, install the valve spring, the valve spring retainer and the valve spring
retainer keys.
2. Relieve the air pressure from the cylinder.
3. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
Using the special tool, compress the valve spring and install the camshaft roller follower.
4. Install the spark plug. 5. Depending on the valve spring being serviced, install the LH or RH
valve cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Valve Spring Installed Length > Page 1919
Valve Spring: Service and Repair Valve Spring Free Length
Valve Spring Free Length
1. Measure the free length of each valve spring.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Valve Spring Installed Length > Page 1920
Valve Spring: Service and Repair Valve Spring Squareness
Valve Spring Squareness
1. Measure the out-of-square on each valve spring.
^ Turn the valve spring and observe the space between the top of the valve spring and the square.
Install a new valve spring if out of square.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Valve Spring Installed Length > Page 1921
Valve Spring: Service and Repair Valve Spring Strength
Valve Spring Strength
Special Tool(s)
1. Use a spring tester to check the valve spring for correct strength at the specified valve spring
length.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Testing and Inspection
Valve: Testing and Inspection
Valve Inspection
1. Inspect the following valve areas:
1 The end of the stem for grooves or scoring
2 The valve face and the edge for pits, grooves or scores
3 The valve head for signs of burning, erosion, warpage and cracking
4 The valve margin for wear
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Valve Stem Diameter
Valve: Service and Repair Valve Stem Diameter
Valve Stem Diameter
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the
diameter is within specification.
^ If out of specification, install new components as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Valve Stem Diameter > Page 1927
Valve: Service and Repair Valve Stem to Valve Guide Clearance
Valve Stem to Valve Guide Clearance
Special Tools
NOTE: Valve stem diameter must be within specifications before checking valve stem to valve
guide clearance.
1. NOTE: If necessary, use a magnetic base.
Install a valve clearance gauge on the valve stem and install a dial indicator. Lower the valve until
the valve clearance gauge contacts the upper surface of the valve guide.
2. Move the valve clearance gauge toward the indicator and zero the indicator. Move the valve
clearance gauge away from the indicator and note the
reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Valves with
oversize stems will need to be installed if out of specification.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-9-7 > May > 09 >
Engine - FEAD Idler Pulley Noise During Cold Start
Drive Belt: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05.
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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 09-9-7 > May > 09 >
Engine - FEAD Idler Pulley Noise During Cold Start > Page 1937
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-9-7 > May
> 09 > Engine - FEAD Idler Pulley Noise During Cold Start
Drive Belt: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05.
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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 09-9-7 > May
> 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1943
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Page 1944
Drive Belt: Diagrams
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Front End Accessory Drive (FEAD) - Exploded View, 4.6L (3V)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
Accessory Drive
Inspection and Verification CAUTION: Under no circumstances should the accessory drive belt,
tensioner or pulleys be lubricated as potential damage to the belt material and tensioner damping
mechanism will occur. Do not apply any fluids or belt dressing to the accessory drive belt or
pulleys.
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
Visual Inspection Chart
Visual Inspection Chart
3. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, power steering
cavitations at low temperatures, variable camshaft timing (VCT) tick or generator whine.
4. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
5. NOTE: Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be considered
acceptable. If damage exceeds the acceptable limit or
any chunks are found to be missing from the ribs, a new belt must be installed.
Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 inch) can be
considered acceptable. If cracks exceed this standard, install a new belt.
6. The condition of the V-ribbed drive belt should be compared against the illustration and
appropriate action taken.
1 Small scattered deposits of rubber material. This is not a concern, therefore, installation of a new
belt is not required.
2 Longer deposit areas building up to 50% of the rib height. This is not considered a concern but it
can result in excessive noise. If noise is apparent, install a new belt.
3 Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a new belt.
V-Ribbed Serpentine Belt With Piling
NOTE: Piling is an excessive buildup in the V-grooves of the belt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1947
V-Ribbed Serpentine Belt With Piling
7. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this,
install a new accessory drive belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
V-Ribbed Serpentine Belt With Chunks Of Rib Missing
8. If the concern is not visually evident, verify the symptom and GO to Symptom Chart. See:
Symptom Related Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1948
Drive Belt: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1949
Symptom Chart (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1950
Drive Belt: Component Tests and General Diagnostics
Drive Belt - Noise/Flutter
Drive Belt - Noise/Flutter Drive belt chirp occurs due to pulley misalignment or excessive pulley
runout. It can be the result of a damaged or incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
CAUTION: Do not apply any fluids or belt dressing to the accessory drive belt or pulleys.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on
an accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start-up and shut down or during very rapid
engine acceleration and decelerations, such as:
^ wide open throttle 1-2 and 2-3 shifts or 2-3 and 3-4 back out shifts on automatic transmissions.
^ wide open throttle 1-2 and 2-3 shifts and any combination of rapid downshifting on manual
transmissions.
These special short-term transient events are expected, and are due to the higher system inertias
required to meet the electrical and cooling demands on today's vehicle systems. Constant or
reoccurring drive belt squeal can occur:
^ if the A/C discharge pressure goes above specifications:
^ the A/C system is overcharged.
^ the A/C condenser core airflow is blocked.
^ if the A/C off equalized pressure (the common discharged and suction pressure that occurs after
several minutes) exceeds specifications.
^ if any of the accessories are damaged or have a worn or damaged bearing. All accessories
should be rotatable by hand in the unloaded condition. If not, inspect the accessory.
^ if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has
been exposed to fluid contamination during vehicle operation, such as leaks from the power
steering system, A/C system or cooling system, clean all pulleys with soap and water, rinse with
clean water and install a new accessory drive belt. If the drive belt has been exposed to fluids in a
localized area during routine vehicle service, such as replacement of hoses or fluids, the drive belt
and pulleys should be washed with soap and water immediately (prior to starting the engine), and
rinsed with clean water.
^ if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive
belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will
release tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal
installation wear range window, install a new accessory drive belt.
^ NOTE: The accessory drive belt tensioner arm should rotate freely without binding.
Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.
Drive Belt - Incorrect Installation
Drive Belt - Incorrect Installation
CAUTION: Incorrect accessory drive belt installation will cause excessive drive belt wear and can
cause the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt
tracks incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive
belt.
Incorrect Installation
Incorrect Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1951
Correct Installation
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the
accessory drive belt rides beyond the edge of the pulleys, noise and premature wear will occur.
Make sure the accessory drive belt rides correctly on the pulley. If an accessory drive belt tracking
condition exists, proceed with the following:
^ Visually check the accessory drive belt tensioner for damage, especially the mounting pad
surface. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will
be out of position. This will result in chirp and squeal noises.
^ With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.
^ Check all accessories, mounting brackets and the accessory drive belt tensioner for any
interference that would prevent the component from mounting correctly. Correct any interference
condition and recheck the accessory drive belt tracking.
^ Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware
to specification. Recheck the accessory drive belt tracking.
Belt Tensioner - Mechanical
Belt Tensioner - Mechanical The only mechanical check that needs to be made is a check for
tensioner stick, grab or bind.
1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under
Description and Operation.
2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Using a suitable, commercially available serpentine belt tensioner release tool, release the tension
on the belt and detach the accessory drive belt in the area of the tensioner.
3. Using a suitable, commercially available serpentine belt tensioner release tool, move the
tensioner from its relaxed position, through its full stroke
and back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that
there is tension on the tensioner spring.
4. Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition.
Install a new accessory drive belt tensioner if
necessary.
5. Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination
and repair any leaks. Install a new accessory drive
belt tensioner as necessary.
6. If the accessory drive belt tensioner meets the above criteria, proceed to testing the tensioner
dynamically. If the accessory drive belt tensioner
does not meet the above criteria, install a new tensioner.
Belt Tensioner - Dynamics
Belt Tensioner - Dynamics The accessory drive belt tensioner can be checked dynamically as
follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory
drive tensioner should move (respond) when the air
conditioning clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory
drive belt tensioner movement is excessive without air conditioning clutch cycling or engine
acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in the belt) can
cause excessive accessory drive belt tensioner movement. Check rideout condition by installing a
new belt. If excessive accessory drive belt tensioner movement still exists, install a new accessory
drive belt tensioner.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Page 1952
Drive Belt: Service and Repair
Accessory Drive Belt - 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. 2. Rotate the accessory drive belt tensioner clockwise and
remove the accessory drive belt.
3. To install, reverse the removal procedure.
^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.6L (3V).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Service and Repair
Drive Belt Tensioner: Service and Repair
Accessory Drive Belt Tensioner - 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. 2. Rotate the accessory drive belt tensioner clockwise and
remove the accessory drive belt.
3. Remove the bolts and the accessory drive belt tensioner.
^ To install, tighten to 25 Nm (18 ft. lbs.).
4. To install, reverse the removal procedure.
^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.6L (3V).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair
Engine Mount: Service and Repair
Engine Support Insulators
Special Tools
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Page 1959
Removal and Installation
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the engine cooling fan. 3. Remove the throttle body
(TB). 4. Remove the alternator. 5. Disconnect the positive crankcase ventilation (PCV) valve hose.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Page 1960
6. Remove the bolts and position the heated PCV fitting aside.
7. Disconnect the evaporative emission (EVAP) hose.
8. Remove the 5 pushpins and the splash shield.
9. Remove the RH engine support insulator upper nuts.
^ To install, tighten to 90 Nm (66 ft. lbs.).
10. Remove the LH engine support insulator through bolt.
^ To install, tighten to 103 Nm (76 ft. lbs.).
11. Install the special tools and raise the engine approximately 70 mm (2.75 inch).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Page 1961
RH side 12. Remove the RH engine support insulator lower nut.
^ To install, tighten to 90 Nm (66 ft. lbs.).
13. Remove the RH engine support insulator. Four wheel drive (4WD) vehicles 14. Remove the
bolts and allow the stabilizer bar to hang freely.
^ To install, tighten to 70 Nm (52 ft. lbs.).
15. WARNING: Secure the axle to the jack with a safety strap. Failure to follow these instructions
may result in personal injury.
Support the axle housing with a suitable jack stand.
16. Disconnect the vent hose from the differential housing vent tube.
17. CAUTION: Any time bolts, washers, spacers or nuts are loosened in the differential support for
any reason, install new components to
prevent damage.
Remove and discard the 3 bolts and 3 flag nuts. ^
To install, tighten to 66 Nm (49 ft. lbs.).
18. Lower the differential housing approximately 25 mm (1 inch).
LH side 19. Remove the LH engine support insulator nut.
^ To install, tighten to 90 Nm (66 ft. lbs.).
20. Remove the engine support insulator. 21. To install, reverse the removal procedure.
^ If equipped, install new differential housing bolts and flag nuts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 09-9-7 > May > 09 >
Engine - FEAD Idler Pulley Noise During Cold Start
Idler Pulley: Customer Interest Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05.
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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 09-9-7 > May > 09 >
Engine - FEAD Idler Pulley Noise During Cold Start > Page 1970
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 09-9-7 >
May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start
Idler Pulley: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05.
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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 09-9-7 >
May > 09 > Engine - FEAD Idler Pulley Noise During Cold Start > Page 1976
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Page 1977
Idler Pulley: Service and Repair
Accessory Drive Belt Idler Pulley - 4.6L (3V)
Removal and Installation
1. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery and
Induction. 2. Rotate the accessory drive belt tensioner clockwise and remove the drive belt.
3. NOTE: The 4.6L (3V) has 3 idler pulleys, an upper RH, an upper LH and a lower LH.
Remove the bolt and the accessory drive belt idler pulley. ^
To install, tighten to 25 Nm (18 ft. lbs.).
4. To install, reverse the removal procedure.
^ For correct belt routing, refer to Accessory Drive, Component Locations - 4.6L (3V).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure minimum at 2,000 rpm (engine at normal operating temperature)
........................................................................................... 517 kPa (75 psi)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 1982
Engine Oil Pressure: Testing and Inspection
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure
Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating
temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5.
The oil pressure should be within specifications. 6. If the pressure is not within specification, check
the following possible sources:
^ Insufficient oil
^ Oil leakage
^ Worn or damaged oil pump
^ Oil pump screen cover and tube
^ Excessive main bearing clearance
^ Excessive connecting rod bearing clearance
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Service and Repair
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair
Oil Level Indicator and Tube
Material
Removal and Installation
1. Remove the LH exhaust manifold. 2. Remove the oil level indicator and tube bolt.
^ To install, tighten to 10 Nm (89 inch lbs.).
3. Remove the oil level indicator and tube from the cylinder block. 4. Remove and discard the
O-ring seal.
5. NOTE: Install a new oil level indicator tube O-ring seal and lubricate it with clean engine oil prior
to installation.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil Capacity
Includes filter change ...........................................................................................................................
............................................................... 6.0L (6.5 qt)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 1990
Engine Oil: Fluid Type Specifications
Engine Oil
U.S. .........................................................................................................................................
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Canada
....................................................................................................................................................
Motorcraft SAE 5W-20 Super Premium Motor Oil
Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only have the
API Certification mark and meet the requirements of Ford Specification WSS-M2C930-A.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Information > Tools and Equipment
Oil Cooler: Tools and Equipment
1/2" Oil Cooler Line Remover
AST tool# 8024
1/2" Oil Cooler Line Remover used for R and R of Transmission Oil Cooler Lines.
- Used for R and R of Transmission Oil Cooler Lines
- Quick Line Removal
- Black-Anodized Aluminum Construction
- See Application Chart
- Included in the #8110 Line Disconnect Set.
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair
Oil Filter Adapter: Service and Repair
Oil Filter Adapter
Material
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Drain the engine cooling system. For additional information,
refer to Cooling System. 3. Drain the engine oil.
^ Install the drain plug and tighten to 23 Nm (17 ft. lbs.).
4. Disconnect the engine oil pressure switch electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Page 1997
5. Disconnect the lower radiator hose and position it aside. 6. Remove and discard the engine oil
filter.
^ To install, lubricate the oil filter gasket with clean engine oil and tighten until the seal makes
contact. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
7. Remove the 4 bolts and the oil filter adapter.
^ To install, tighten to 25 Nm (18 ft. lbs.).
8. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing
surfaces.
Remove and discard the oil filter adapter gasket. ^
Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
directions on the packaging.
^ Inspect the mating surfaces.
9. To install, reverse the removal procedure.
^ Fill the engine with clean engine oil.
10. Fill and bleed the engine cooling system. For additional information, refer to Cooling System.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Tighten the bolt in 3 stages in the sequence shown.
Stage 1: Tighten to ..............................................................................................................................
........................................ 2 Nm (18 inch lbs.). Stage 2: Tighten to .....................................................
................................................................................................................... 20 Nm (15 ft. lbs.). Stage
3: Tighten an ........................................................................................................................................
........................... additional 60 degrees.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2001
Oil Pan: Service and Repair
Oil Pan
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the front axle, if equipped. 3. Remove the stabilizer
bar. 4. Remove the drain plug and drain the engine oil Install the drain plug when finished.
^ Tighten to 23 Nm (17 ft. lbs.).
5. Remove the nut and position the power steering pressure (PSP) hose bracket aside.
6. Remove the nut and position the battery cable bracket aside.
7. Disconnect the oil temperature sensor electrical connector. 8. Detach the wiring harness
retainers from the RH side oil pan bolts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2002
9. Remove the bolts and the oil drain splash shield.
10. If equipped with a block heater, detach the block heater wiring harness retainer from the LH
side oil pan bolt.
11. Remove the bolts, the oil pan and the gasket. - Discard the gasket.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing
surfaces. Failure to follow these directions can cause future oil leaks.
Clean and inspect the sealing surfaces with silicone gasket remover, metal surface prep, and a
plastic scraper. Follow the directions on the packaging.
2. NOTE: If the oil pan and gasket are not secured within 4 minutes of sealer application, the
sealant must be removed and the sealing surfaces
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging.
Apply silicone gasket and sealant in 2 places as shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2003
3. NOTE: If the oil pan and gasket are not secured within 4 minutes of sealer application, the
sealant must be removed and the sealing surfaces
cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging.
Apply silicone gasket and sealant in 2 places as shown.
4. Position a new oil pan gasket and the oil pan and install the bolts finger-tight. 5. Tighten the bolt
in 3 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 60 degrees.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2004
6. If equipped with a block heater, attach the block heater wiring harness retainer to the LH oil pan
bolt.
7. Position the oil drain splash shield and install the bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
8. Attach the wiring harness retainers to the RH oil pan bolts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications > Page 2005
9. Connect the oil temperature sensor electrical connector.
10. Attach the battery cable bracket and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
11. Attach the PSP hose bracket and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
12. Install the stabilizer bar. 13. Install the front axle, if equipped. 14. Fill the engine with clean
engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations > Page 2009
C103
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair
Oil Pick Up/Strainer: Service and Repair
Oil Pump Screen and Pickup Tube
Material
Removal
1. Remove the oil pan. 2. Remove the bolts and the oil pump screen and pickup tube.
Installation
1. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can
cause foam in the lubrication system,
low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with
clean engine oil prior to installation.
Position the oil pump screen and pickup tube and install the bolts. ^
Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 inch lbs.).
^ Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 ft. lbs.).
2. Install the oil pan.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Page 2013
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure minimum at 2,000 rpm (engine at normal operating temperature)
........................................................................................... 517 kPa (75 psi)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 2018
Engine Oil Pressure: Testing and Inspection
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Oil Pressure
Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating
temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5.
The oil pressure should be within specifications. 6. If the pressure is not within specification, check
the following possible sources:
^ Insufficient oil
^ Oil leakage
^ Worn or damaged oil pump
^ Oil pump screen cover and tube
^ Excessive main bearing clearance
^ Excessive connecting rod bearing clearance
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch,
Engine > Component Information > Description and Operation
Oil Temperature Sensor/Switch: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical EOT Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance changes 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 sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control
gains and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM begins reducing power by disabling engine cylinders.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Customer Interest for Intake Manifold: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set
Intake Manifold: Customer Interest Engine - MIL ON/DTC's P2000-P2008/P2015/P2020 Set
TSB 06-7-10
04/17/06
MIL ON WITH DTC P2004 THROUGH P2008, P151A, P2015, P2020 - 4.6L 3V
FORD: 2005-2006 Mustang 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
This article supersedes TSB 05-25-15 to update the vehicle model years.
ISSUE Some 2005-2006 Mustang GT, 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport
Trac vehicles may exhibit the malfunction indicator lamp (MIL) on, with diagnostic trouble codes
(DTCs) P2004 through P2008, P151A, P2015, and P2020. All of these codes are associated with
the charge motion control valve (CMCV), actuator motor, and/or linkage concerns.
ACTION Refer to the following Service Procedure to determine if a CMCV Actuator Kit should be
installed.
SERVICE PROCEDURE
1. Does the vehicle exhibit DTC P2004, P2005, P2006, and/or P2007 (stuck CMCV
motor/linkages)?
a. If so, visually inspect CMCV linkages to ensure they are free of interference from improper wire
routings or foreign objects. If there is interference, resolve interference as needed. If there is no
interference or disconnected/damaged wiring to CMCV actuator proceed to Step 2.
b. If not, proceed to Step 2.
2. Remove intake manifold from engine as outlined in the Workshop Manual, Section 303-01.
Position the intake manifold on a clean flat work surface, with bottom side up as shown in the
CMCV Actuator Kit instruction sheet. Take care to prevent debris from entering the runner ports.
CAUTION
DO NOT REST THE MANIFOLD ON THE INTAKE MANIFOLD FLANGE, AS IRREPARABLE
DAMAGE MAY OCCUR TO THE CMCV PLATES.
NOTE
VISUALLY INSPECT THAT ALL CMCV PLATES ARE INTACT. BENT PLATES OR OTHERWISE
DAMAGED COMPONENTS WILL REQUIRE ENTIRE MANIFOLD REPLACEMENT (REFER TO
FIGURE 1 IN CMCV ACTUATOR KIT INSTRUCTION SHEET).
3. Disconnect the CMCV linkages from actuator motor by removing the two (2) clips (Figure 1).
Discard clips.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Customer Interest for Intake Manifold: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 2030
4. Rotate each CMCV shaft (right hand and left hand) by hand, to verify that the system does not
stick or bind. The shafts should rotate freely and any sticking or binding will require replacement of
the entire intake manifold.
5. If the components inspected in Steps 1, 2, and 3 are OK, then replace CMCV actuator motor by
following procedure included in the service kit.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060710A 2005-2006 Mustang 4.6L 1.8 Hrs.
3V: Inspect CMCV plates, Replace Intake Manifold, Includes Time To Check For Diagnostic
Trouble Codes, Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A,
9531A, 9424A, 9926A, 12650D24, 12650D35)
060710B 2005-2006 Mustang 4.6L 1.7 Hrs
3V: Inspect CMCV plates, Replace CMCV, Includes Time To Check For Diagnostic Trouble Codes,
Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A, 9531A, 9424A,
9926A, 12650D24, 12650D35)
06071OC 2006 Explorer, 1.9 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace Intake Manifold
Includes Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do
Not Use With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 12650D24, 12650D35)
060710D 2006 Explorer, 1.8 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace CMCV, Includes
Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do Not Use
With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 1650D24, 12650D35)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Customer Interest for Intake Manifold: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 2031
DEALER CODING
CONDITION
BASIC PART NO. CODE
9G730 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set
Intake Manifold: All Technical Service Bulletins Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set
TSB 06-7-10
04/17/06
MIL ON WITH DTC P2004 THROUGH P2008, P151A, P2015, P2020 - 4.6L 3V
FORD: 2005-2006 Mustang 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
This article supersedes TSB 05-25-15 to update the vehicle model years.
ISSUE Some 2005-2006 Mustang GT, 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport
Trac vehicles may exhibit the malfunction indicator lamp (MIL) on, with diagnostic trouble codes
(DTCs) P2004 through P2008, P151A, P2015, and P2020. All of these codes are associated with
the charge motion control valve (CMCV), actuator motor, and/or linkage concerns.
ACTION Refer to the following Service Procedure to determine if a CMCV Actuator Kit should be
installed.
SERVICE PROCEDURE
1. Does the vehicle exhibit DTC P2004, P2005, P2006, and/or P2007 (stuck CMCV
motor/linkages)?
a. If so, visually inspect CMCV linkages to ensure they are free of interference from improper wire
routings or foreign objects. If there is interference, resolve interference as needed. If there is no
interference or disconnected/damaged wiring to CMCV actuator proceed to Step 2.
b. If not, proceed to Step 2.
2. Remove intake manifold from engine as outlined in the Workshop Manual, Section 303-01.
Position the intake manifold on a clean flat work surface, with bottom side up as shown in the
CMCV Actuator Kit instruction sheet. Take care to prevent debris from entering the runner ports.
CAUTION
DO NOT REST THE MANIFOLD ON THE INTAKE MANIFOLD FLANGE, AS IRREPARABLE
DAMAGE MAY OCCUR TO THE CMCV PLATES.
NOTE
VISUALLY INSPECT THAT ALL CMCV PLATES ARE INTACT. BENT PLATES OR OTHERWISE
DAMAGED COMPONENTS WILL REQUIRE ENTIRE MANIFOLD REPLACEMENT (REFER TO
FIGURE 1 IN CMCV ACTUATOR KIT INSTRUCTION SHEET).
3. Disconnect the CMCV linkages from actuator motor by removing the two (2) clips (Figure 1).
Discard clips.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 2037
4. Rotate each CMCV shaft (right hand and left hand) by hand, to verify that the system does not
stick or bind. The shafts should rotate freely and any sticking or binding will require replacement of
the entire intake manifold.
5. If the components inspected in Steps 1, 2, and 3 are OK, then replace CMCV actuator motor by
following procedure included in the service kit.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060710A 2005-2006 Mustang 4.6L 1.8 Hrs.
3V: Inspect CMCV plates, Replace Intake Manifold, Includes Time To Check For Diagnostic
Trouble Codes, Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A,
9531A, 9424A, 9926A, 12650D24, 12650D35)
060710B 2005-2006 Mustang 4.6L 1.7 Hrs
3V: Inspect CMCV plates, Replace CMCV, Includes Time To Check For Diagnostic Trouble Codes,
Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A, 9531A, 9424A,
9926A, 12650D24, 12650D35)
06071OC 2006 Explorer, 1.9 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace Intake Manifold
Includes Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do
Not Use With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 12650D24, 12650D35)
060710D 2006 Explorer, 1.8 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace CMCV, Includes
Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do Not Use
With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 1650D24, 12650D35)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 2038
DEALER CODING
CONDITION
BASIC PART NO. CODE
9G730 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Page 2039
Intake Manifold: Specifications
Intake Manifold Bolts
Stage 1: Tighten to 2 Nm (18 inch lbs.). Stage 2: Tighten to 10 Nm (89 inch lbs.).
Throttle body bolts ...............................................................................................................................
................................................. 10 Nm (89 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Page 2040
Intake Manifold: Service and Repair
Intake Manifold
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Page 2041
Removal
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.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not
running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel
system pressure must be relieved to prevent accidental spraying of fuel, causing a fire hazard.
Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air
Induction. 2. Remove the air cleaner outlet pipe. For additional information, refer to Fuel Delivery
and Air Induction. 3. Remove the fuel rail and injectors. 4. Disconnect the electronic throttle body
(TB) electrical connector. 5. Disconnect the evaporative emissions (EVAP) tube from the intake
manifold. 6. Disconnect the throttle position (TP) sensor electrical connector. 7. Disconnect the
positive crankcase ventilation (PCV) hose from the heated PCV fitting on the intake manifold. 8.
Remove the bolts and position the heated PCV fitting aside.
^ Remove and discard the O-ring seal.
9. Detach the wiring harness retainers from the intake manifold.
10. Disconnect the charge motion control valve (CMCV) electrical connector. 11. Remove the bolts
and position the intake manifold forward. 12. Disconnect the brake booster vacuum hose from the
rear of the intake manifold. 13. Disconnect the vacuum hose from the rear of the intake manifold.
14. Remove the intake manifold and the gaskets.
^ Discard the gaskets.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old gaskets.
NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the
packaging.
NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at
the rear of the intake manifold. Use extreme care during the installation of the intake manifold to
prevent any pinching of electrical and vacuum harnesses.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Page 2042
Using new intake manifold gaskets, position the intake manifold.
2. Connect the vacuum hose to the rear of the intake manifold. 3. Connect the brake booster hose
to the rear of the intake manifold. 4. Install the intake manifold bolts and tighten the bolts in the
sequence shown in 2 stages.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 10 Nm (89 inch lbs.).
5. Connect the CMCV electrical connector. 6. Attach the wiring harness retainers to the intake
manifold. 7. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 8.
Connect the PCV hose to the heated PCV fitting on the intake manifold. 9. Connect the TP sensor
electrical connector.
10. Connect the EVAP hose to the intake manifold. 11. Connect the electronic TB electrical
connector. 12. Install the fuel rail and injectors. 13. Install the air cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Diagrams
Crankshaft Main Bearing Seal: Diagrams
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Diagrams > Page 2047
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Seal
Special Tools
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Diagrams > Page 2048
Removal
1. Remove the flexplate. 2. Remove the engine-to-transmission spacer plate. 3. Using the special
tools, remove the crankshaft oil slinger.
^ Discard the crankshaft oil slinger.
4. Using the special tools, remove the crankshaft rear seal.
^ Discard the crankshaft rear seal.
Installation
1. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the special tools, install the crankshaft rear seal.
2. Using the special tools, install the crankshaft rear oil slinger.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Diagrams > Page 2049
3. Install the engine-to-transmission spacer plate. 4. Install the flexplate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 Seal
Special Tools
Material
Removal
1. Remove the crankshaft pulley. 2. Using the special tool, remove the crankshaft front seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Page 2053
Installation
1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft front seal.
3. Install the crankshaft pulley.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Valve Seals
Special Tools
Material
Removal
1. Depending on the valve seal being serviced, remove the LH or RH valve cover. 2. Remove the
spark plug. 3. Rotate the crankshaft until the piston for the valve seal being serviced is at the top of
its stroke with the intake valve and the exhaust valves closed.
4. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
Using the special tool, compress the valve spring and remove the camshaft roller follower.
5. Use compressed air in the cylinder to hold both valves in position.
^ Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
6. 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2057
CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into their original locations.
Using the special tool, compress the valve spring and remove the valve spring retainer keys.
7. Remove the valve spring retainer, the valve spring and the valve seal.
^ Discard the valve seal.
8. Inspect the components.
Installation
1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation.
Position a new valve seal onto the valve stem.
2. Using the special tool, install the new valve seal.
3. Using the special tool, install the valve spring, the valve spring retainer and the valve spring
retainer keys.
4. Relieve the air pressure from the cylinder.
5. CAUTION: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation
into their original locations.
Using the special tool, compress the valve spring and install the camshaft roller follower.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Page 2058
6. Install the spark plug. 7. Depending on the valve seal being serviced, install the LH or RH valve
cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations > Page 2063
C103
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Description and Operation
Oil Temperature Sensor/Switch: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical EOT Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance changes 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 sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control
gains and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM begins reducing power by disabling engine cylinders.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Service and Repair
Camshaft Gear/Sprocket: Service and Repair
Special Tool(s)
Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional
information, refer to Camshaft - RH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional
information, refer to Camshaft - LH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special
tool is removed or out of placement, the engine front cover must be removed and the engine must
be retimed. For additional information, refer to Timing Drive Components. See:
Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
- If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
- If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Service and Repair > Page 2071
6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or
spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
Installation
1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new
camshaft phaser and sprocket.
2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and
sprocket using the scribed marks, or damage to
valves and pistons will result.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used
as a lifting or leveraging device.
Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.
3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional
information, refer to Camshaft - RH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional
information, refer to Camshaft - LH. See: Camshaft,
Lifters and Push Rods/Camshaft/Service and Repair
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Specifications
Timing Chain Tensioner: Specifications
Timing Chain Tensioners
Tighten to .............................................................................................................................................
................................................ 25 Nm (18 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2078
Tighten the engine front cover fasteners in the sequence shown to
......................................................................................................... 25 Nm (18 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2079
Timing Cover: Service and Repair
Engine Front Cover
Special Tools
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2080
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2081
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2082
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2083
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the drain plug and drain the engine oil.
^ To install, tighten to 23 Nm (17 ft. lbs.).
3. Remove the cooling fan shroud. 4. Remove the RH side idler pulley. 5. Remove the RH valve
cover. 6. Remove the LH valve cover. 7. Remove the nut and position the RH radio interference
capacitor aside. 8. Disconnect the RH camshaft position (CMP) sensor electrical connector. 9.
Remove the nut and the cooling fan wiring harness bracket.
10. Remove the nut and position the LH radio interference capacitor aside. 11. Disconnect the LH
CMP sensor electrical connector. 12. Remove the bolts and the coolant pump pulley. 13. Remove
the nuts and detach the battery cable bracket from the power steering pump stud bolts. 14. Detach
the wiring harness retainer from the power steering pump stud bolt. 15. Remove the stud bolts and
position the power steering pump aside.
^ Support the power steering pump with a length of mechanic's wire.
16. Remove the nut and detach the power steering pressure (PSP) hose bracket from the battery
cable bracket. 17. Remove the nut and detach the battery cable bracket from the engine front
cover. 18. Remove the nut and detach the transmission cooler tube bracket from the engine front
cover. 19. Disconnect the crankshaft position (CKP) sensor electrical connector. 20. Remove the
crankshaft pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
21. Using the special tool, remove the crankshaft pulley.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2084
22. Using the special tool, remove the crankshaft front seal.
^ Discard the crankshaft front seal.
23. Remove the oil pan-to-engine front cover bolts. 24. Remove the engine front cover bolts and
stud bolts. 25. Remove the engine front cover from the engine front cover-to-cylinder block dowel.
^ Remove and discard the engine front cover gaskets.
Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
Clean the mating surfaces with silicone gasket remover, metal surface prep and a plastic scraping
tool. Follow the directions on the packaging.
2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of old sealant.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and
the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface
prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil
leakage.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block mating
surface and the oil pan-to-cylinder block mating surface at the locations shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2085
3. Install new engine front cover gaskets on the engine front cover. Position the engine front cover
onto the dowels. Install the fasteners finger tight.
4. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2086
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2087
5. Loosely install the oil pan-to-engine front cover bolts, then tighten the bolts in 2 stages in the
sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 60 degrees.
6. Lubricate the engine front cover and a new crankshaft front seal inner lip with clean engine oil.
7. Using the special tools, install the crankshaft front seal.
8. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with silicone gasket remover and metal surface
prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil
leakage.
Apply silicone gasket sealant to the Woodruff key slot in the crankshaft pulley.
9. Using the special tool, install the crankshaft pulley.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 2088
10. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.
11. Connect the CKP sensor electrical connector. 12. Attach the transmission cooler tube bracket
to the engine front cover and install the nut.
^ Tighten to 12 Nm (9 ft. lbs.).
13. Attach the battery cable bracket to the front cover and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
14. Attach the PSP hose bracket to the battery cable bracket and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).
15. Position the power steering pump and install the stud bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
16. Attach the wiring harness retainer to the power steering pump stud bolt. 17. Position the battery
cable bracket on the power steering pump stud bolts and install the nuts.
^ Tighten to 10 Nm (89 inch lbs.).
18. Position the coolant pump pulley and install the bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
19. Connect the LH CMP sensor electrical connector. 20. Position the LH radio interference
capacitor and install the nut.
^ Tighten to 25 Nm (18 ft. lbs.).
21. Position the cooling fan wiring harness bracket and install the nut. 22. Connect the RH CMP
sensor electrical connector. 23. Position the RH radio interference capacitor and install the nut.
^ Tighten to 25 Nm (18 ft. lbs.).
24. Install the LH valve cover. 25. Install the RH valve cover. 26. Install the RH side idler pulley. 27.
Install the cooling fan shroud. 28. Fill the engine with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
C1451
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page
2094
C1452
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Page 2095
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAMSHAFT TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake phase shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default
mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM)
determines the phase angle based on air flow, engine oil temperature and engine coolant
temperature. At part and wide open throttle the PCM determines the phase angle based on engine
RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine
power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque.
In addition, some VCT system applications can eliminate the need for an external exhaust gas
recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the
overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS
and DEPS systems are used.
Variable Camshaft Timing (VCT) System
VCT System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments. 1. The PCM receives input signals from the intake air temperature (IAT)
sensor, engine coolant temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system does not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It continually updates the VCT
solenoid duty cycle until the desired position is achieved. A difference between the desired and
actual camshaft position represents a position error in the PCM VCT control loop. The PCM
disables the VCT and places the camshaft in a default position if a concern is detected. A related
DTC is also set when the concern is detected.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Diagrams > Page 2096
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the camshaft timing.
One half of the VCT actuator is coupled to the camshaft and the other half is connected to the
timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When
the flow of oil is shifted from one side of the chamber to the other, the differential change in oil
pressure forces the camshaft to rotate in either an advance or retard position depending on the oil
flow.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Service and Repair
Variable Valve Timing Solenoid: Service and Repair
VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID
Removal and Installation
1. Remove the valve cover. 2. Remove the bolt and the VCT oil control solenoid.
- To install, tighten to 5 Nm (44 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Fuel Pressure
Key on, engine off.................................................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
............................................................ 630-850 RPM
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2111
Exploded View
Removal and Installation
NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector.
Vehicles equipped with a 4.0L (SOHC) engine
1. Detach the wiring harness retainer from the air cleaner outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2112
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and
remove the air cleaner cover. 5. Remove the air cleaner element.
6. NOTE: Clean the inside of the air cleaner tray.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
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.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow
it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to
make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key
and wait 3 seconds to pressurize the fuel system.
Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame
scuff plate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications > Page 2120
Firing Order: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Number One Cylinder: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2129
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2130
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2131
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2132
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2133
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2134
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
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Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
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3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2136
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2137
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2138
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page
2139
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions 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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > General Specifications
Spark Plug: Specifications General Specifications
Item.......................................................................................................................................................
..............................................................Specification
Spark plug gap (not adjustable)............................................................................................................
.....................................1.02-1.28 mm 0.040-0.050 in)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > General Specifications > Page 2142
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2143
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
....................................................................... PZT1F
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2144
Spark Plug: Testing and Inspection
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2145
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2146
Spark Plug: Service and Repair
SPARK PLUGS
Exploded View
Removal and Installation
1. Disconnect the ignition coil electrical connectors. 2. Remove the ignition coil bolts.
- To install, tighten to 5 Nm (44 lb-in).
3. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease
removal.
Remove the ignition coils.
4. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is re-used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
5. CAUTION: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark
plug is adjusted. Install a new spark
plug if the gap is out of specification.
Inspect the spark plugs. Install new spark plugs as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 2147
6. To install, reverse the removal procedure.
- Apply a light film of brake caliper grease to the inside of the coil boots before installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2151
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 5 compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
If one or more cylinders read 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 2 adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may be
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2152
leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is at least 75% of the highest reading.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
Coolant pump bolts (4.6L) ...................................................................................................................
..................................................... 25 Nm (18 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2156
Water Pump: Service and Repair
Coolant Pump - 4.6L (3V)
Material
Removal and Installation
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. 4. Remove the bolts
and the coolant pump pulley.
^ To install, tighten to 25 Nm (18 ft. lbs.).
5. Remove the bolts and the coolant pump.
^ To install, tighten to 25 Nm (18 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 2157
6. Remove and discard the coolant pump O-ring.
7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old O-ring.
Clean the mating surfaces with a plastic scraper, if necessary, and metal surface prep. Follow the
directions on the packaging.
8. To install, reverse the removal procedure.
^ Install a new coolant pump O-ring. Lubricate the O-ring with clean engine coolant.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity .................................................................................................................................
............................................ 13.9 quarts (13.2 liters)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 2163
Coolant: Fluid Type Specifications
ENGINE COOLANT
Motorcraft Premium Gold Engine Coolant (yellow-colored)
Ford Part Number ................................................................................................................................
.................................................................. VC-7-B Ford Specification ................................................
................................................................................................................................ WSS-M97B51-A1
Note: Add the coolant type originally equipped in your vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair
Coolant Line/Hose: Service and Repair
Coolant Crossover Manifold Assembly
Coolant Crossover Manifold Assembly (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair > Page 2167
Coolant Crossover Manifold Assembly (Part 2)
Removal and Installation
1. Disconnect the battery ground cable. 2. Drain the engine cooling system. For additional
information, refer to Cooling System Draining, Filling and Bleeding. 3. Remove the intake manifold.
4. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator
pulley.
5. Disconnect the electrical connector. 6. Loosen the generator nuts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Service and Repair > Page 2168
^ To install, tighten to 25 Nm (18 ft. lbs.).
7. Remove the generator bracket-to-coolant crossover bolts, and position the generator, bracket
and wiring harness aside as an assembly.
^ To install, tighten to 10 Nm (89 inch lbs.).
8. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 9. Disconnect
the heater hose from the coolant crossover manifold assembly.
10. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 11. Remove
the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets.
^ To install, tighten to 10 Nm (89 inch lbs.).
12. To install, reverse the removal procedure.
^ Install new gaskets.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Service and Repair
Coolant Reservoir: Service and Repair
Coolant Expansion Tank
Material
Material
CAUTION: Allow the engine to cool before removing the coolant expansion tank. The radiator
draws coolant from the coolant expansion tank as the engine cools. If the coolant expansion tank is
removed before the engine cools, the radiator will draw air into the system, resulting in possible
engine damage.
1. Disconnect the coolant overflow hose. 2. If equipped, detach the mass air flow (MAF) sensor
wiring harness retainer. 3. Remove the bolts and the coolant expansion tank.
^ To install, tighten to 7 Nm (62 inch lbs.).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Service and Repair > Page 2172
^ Fill the coolant expansion tank with a 50/50 mixture of coolant and clean, drinkable water.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Description and Operation
Radiator Cooling Fan Motor: Description and Operation
FAN CONTROL
The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C
on/off status, A/C pressure) to determine engine cooling fan needs.
For variable speed electric fan(s):
Edge/MKX, Five Hundred/Freestyle/Montego, Fusion/Milan/MKZ, Crown Victoria/Grand Marquis,
Town Car: FCV Duty Cycle Output From PCM (Negative Duty Cycle)
The PCM controls the fan speed and operation using a duty cycle output on the fan control variable
(FCV) circuit. The fan controller (located at or integral to the engine cooling fan assembly) receives
the FCV command and operates the cooling fan at the speed requested (by varying the power
applied to the fan motor).
For relay controlled fans:
2.0L Focus (with A/C) And Taurus: PCM FC Output State For Cooling Fan Speeds
2.3L Escape: PCM FC Output State For Cooling Fan Speeds
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Description and Operation > Page 2177
Freestar, Monterey: PCM FC Output State For Cooling Fan Speeds
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. Some
applications will have the xFC circuit wired to 2 separate relays.
For 3-speed fans, although the PCM output circuits are called low, medium, and high fan control
(FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Speed Sensor > Component Information > Description and Operation
Radiator Cooling Fan Speed Sensor: Description and Operation
FAN SPEED SENSOR (FSS)
Cooling Fan Clutch With (FSS)
The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a
waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a
relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch
speed increases, the sensor generates a signal with a higher frequency. The powertrain control
module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop
control of the cooling fan clutch.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair
Fan Blade: Service and Repair
Cooling Fan
Special Tools
Removal and Installation
Vehicle equipped with a 4.6L (3V) 1. Remove the air cleaner outlet pipe.
All vehicles 2. Remove the coolant expansion tank. 3. Remove the bolt and position the power
steering fluid reservoir aside.
^ To install, tighten to 10 Nm (89 inch lbs.).
4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the
upper fan shroud.
^ To install, tighten to 7 Nm (62 inch lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair > Page 2184
5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket
bolt.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. Using the special tools, remove the cooling fan.
^ To install, tighten to 55 Nm (41 ft. lbs.).
8. Remove the bolts and separate the fan from the fan clutch.
^ To install, tighten to 7 Nm (62 inch lbs.).
9. If necessary, unclip and disconnect the fan clutch wiring harness.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams
C1158
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams > Page 2188
Fan Clutch: Description and Operation
COOLING FAN CLUTCH
Cooling Fan Clutch With Fan Speed Sensor (FSS)
The cooling fan clutch is an electrically actuated viscous clutch that consists of 3 main elements:
- a working chamber
- a reservoir chamber
- a cooling fan clutch actuator valve and a fan speed sensor (FSS)
The cooling fan clutch actuator valve controls the fluid flow from the reservoir into the working
chamber. Once viscous fluid is in the working chamber, shearing of the fluid results in fan rotation.
The cooling fan clutch actuator valve is activated with a pulse width modulated (PWM) output
signal from the PCM. By opening and closing the fluid port valve, the PCM can control the cooling
fan clutch speed. The cooling fan clutch speed is measured by a Hall-effect sensor and is
monitored by the PCM during closed loop operation.
The PCM optimizes fan speed based on engine coolant temperature (ECT), engine oil temperature
(EOT), transmission fluid temperature (TFT), intake air temperature (IAT), or air conditioning
requirements. When an increased demand for fan speed is requested for vehicle cooling, the PCM
monitors the fan speed through the Hall-effect sensor. If a fan speed increase is required, the PCM
outputs the PWM signal to the fluid port, providing the required fan speed increase.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Diagrams > Page 2189
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams
C1064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2197
C107
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2198
Engine Temperature Sensor: Description and Operation
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical CHT Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases., and the resistance
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.
The CHT sensor is installed in the 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 initiates a
fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern
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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Locations > Page 2199
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair
Fan Shroud: Service and Repair
Cooling Fan Shroud
Special Tools
Removal and Installation
Vehicles equipped with a 4.6L (3V) engine
1. Remove the air cleaner outlet pipe.
All vehicles 2. Remove the coolant expansion tank. 3. Remove the bolt and position the power
steering fluid reservoir aside.
^ To install, tighten to 10 Nm (89 inch lbs.).
4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the
upper fan shroud.
^ To install, tighten to 7 Nm (62 inch lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair > Page 2203
5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket
bolt.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. Using the special tools, remove the cooling fan.
^ To install, tighten to 55 Nm (41 ft. lbs.).
8. Remove the bolts and the lower fan shroud.
^ To install, tighten to 7 Nm (62 inch lbs.).
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Service and Repair
Heater Control Valve: Service and Repair
HEATER CONTROL VALVE
Removal and Installation
Vehicles with 4.0L and oil cooler, without auxiliary climate control
1. With the vehicle in NEUTRAL, position it on a hoist.
All vehicles
2. Drain the engine coolant. 3. Disconnect the 2 inlet and outlet heater hose clamps. 4. Disconnect
the heater control valve vacuum hose.
Vehicles with 4.0L and oil cooler, without auxiliary climate control
5. Remove the heater control valve bolt.
All vehicles
6. Remove the heater control valve.
7. NOTE: Lubricate the coolant hoses with plain water only if needed.
To install, reverse the removal procedure.
8. Fill the engine cooling system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2215
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2216
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2222
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2223
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core
Heater Core: Service and Repair Heater Core
HEATER CORE
Removal and Installation
NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is
removed from the vehicle.
1. Remove the heater core and evaporator core housing. 2. Remove the 2 LH floor duct screws. 3.
Remove the LH floor duct. 4. Remove the 2 RH floor duct screws. 5. Remove the RH floor duct. 6.
Remove the 3 housing brace screws. 7. Remove the housing brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2226
8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover.
10. Remove the heater tube seal. 11. Remove the 4 heater core cover screws. 12. Remove the
heater core cover. 13. Remove the heater core. 14. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2227
Heater Core: Service and Repair Auxiliary Heater Core
AUXILIARY HEATER CORE
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2228
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant.
3. Release the 2 heater hose clamps and disconnect the heater hoses.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Heater Core > Page 2229
4. Remove the rear quarter trim panel.
5. Remove the 2 auxiliary line floorpan bracket nuts.
6. NOTE: The screw and line bracket are located inside the vehicle above the floorpan line bracket.
Remove the 4 line bracket screws and the line bracket.
7. Disconnect the auxiliary harness electrical connector. 8. Remove the 2 auxiliary housing bolts
and auxiliary housing nut.
- To install, tighten to 6 Nm (53 lb-in).
9. Disconnect the 2 auxiliary actuator electrical connectors.
10. Remove the 3 auxiliary mode door actuator screws. 11. Remove the auxiliary mode door
actuator. 12. Remove the 3 auxiliary temperature blend door actuator screws. 13. Remove the
auxiliary temperature blend door actuator. 14. Remove the 4 heater core cover screws. 15.
Remove the heater core cover. 16. Disconnect the 2 heater core hose clamps. 17. Remove the
auxiliary heater core. 18. To install, reverse the removal procedure.
- Lubricate the coolant hoses with plain water only if needed.
19. Fill the engine cooling system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2238
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2239
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2245
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2246
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front
AUXILIARY HEATER OUTLET AND INLET LINE - FRONT
Removal and Installation
1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4.
Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release
the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3
auxiliary line bracket nuts.
- To install, tighten to 6 Nm (53 lb-in).
7. Remove the 3 auxiliary line bracket bolts.
- To install, tighten to 6 Nm (53 lb-in).
8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines.
10. To install, reverse the removal procedure. 11. Fill the engine cooling system,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2249
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear
AUXILIARY HEATER OUTLET AND INLET LINE - REAR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the
spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type
retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose
clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and
disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Auxiliary Heater Outlet and Inlet Line - Front > Page 2250
- To install, tighten to 8 Nm (71 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12.
To install, reverse the removal procedure. 13. Fill the engine cooling system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair
Radiator: Service and Repair
Radiator
Special Tools
Removal and Installation
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Drain the cooling system. For additional information, refer to
Cooling System Draining, Filling and Bleeding.
Vehicles equipped with a 4.6L engine 3. Remove the air cleaner outlet pipe.
All vehicles 4. Remove the coolant expansion tank. 5. Remove the bolt and position the power
steering fluid reservoir aside.
^ To install, tighten to 10 Nm (89 inch lbs.).
6. Release the clamp and disconnect the upper radiator hose. 7. Release the clamp and
disconnect the lower radiator hose. 8. Detach the lower radiator hose retainer from the lower fan
shroud. 9. Detach the transmission cooler hose retainer from the RH radiator support bracket.
10. Remove the 4 lower radiator air deflector pushpins. 11. Remove the latch assemblies from the
transmission cooler tubes.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2254
12. Using the special tool, disconnect the transmission cooler tubes.
13. Remove the upper fan shroud bolts, then unclip the upper fan shroud from the lower fan shroud
and remove the upper fan shroud.
^ To install, tighten to 7 Nm (62 inch lbs.).
14. Disconnect the fan clutch electrical connector. 15. Remove the fan clutch wiring harness
bracket bolt.
^ To install, tighten to 7 Nm (62 inch lbs.).
16. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar.
Using the special tools, remove the cooling fan. ^
To install, tighten to 55 Nm (41 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 2255
17. Remove the bolts and the lower fan shroud.
18. NOTE: 4.6L (3V) engine shown, 4.0L SOHC similar.
Detach the A/C tube from the retainer.
19. Remove the radiator support bracket-to-radiator support bolts.
^ To install, tighten to 15 Nm (11 ft. lbs.).
20. Remove the radiator top seal.
21. NOTE: Do not remove the A/C condenser seals.
Deflect the A/C condenser seals and remove the A/C condenser-to-radiator support bracket bolts. ^
Position the A/C condenser aside.
^ To install, tighten to 12 Nm (9 ft. lbs.).
22. Remove the radiator and the radiator support brackets as an assembly. 23. Remove the bolts
and separate the radiator support brackets and the radiator.
^ To install, tighten to 12 Nm (9 ft. lbs.).
24. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation
Radiator Cooling Fan Speed Sensor: Description and Operation
FAN SPEED SENSOR (FSS)
Cooling Fan Clutch With (FSS)
The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a
waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a
relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch
speed increases, the sensor generates a signal with a higher frequency. The powertrain control
module (PCM) uses the frequency signal generated by the FSS as a feedback for closed loop
control of the cooling fan clutch.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
C1064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
2267
C107
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
2268
Engine Temperature Sensor: Description and Operation
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical CHT Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases., and the resistance
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.
The CHT sensor is installed in the 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 initiates a
fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern
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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
2269
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Thermostat Opening Temperature
Starts to open ......................................................................................................................................
............................................. 87-91°C (189-196°F) Fully open ...........................................................
........................................................................................................................................ 100°C
(212°F)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2273
Thermostat: Service and Repair
Thermostat - 4.6L (3V)
Removal and Installation
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding. 2. Remove the throttle body. 3. Disconnect the fuel vapor tube.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2274
4. Remove the bolts and position the thermostat housing cover aside. 5. Remove the O-ring seal
and the thermostat.
Installation
1. Install the thermostat with the spring facing down.
2. NOTE: Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal, if necessary.
Install the O-ring seal.
3. Position the thermostat housing cover and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
4. Connect the fuel vapor hose. 5. Install the throttle body. 6. Fill and bleed the cooling system. For
additional information, refer to Cooling System Draining, Filling and Bleeding.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Coolant pump bolts (4.6L) ...................................................................................................................
..................................................... 25 Nm (18 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2278
Water Pump: Service and Repair
Coolant Pump - 4.6L (3V)
Material
Removal and Installation
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding. 2. Remove the cooling fan. 3. Remove the accessory drive belt. 4. Remove the bolts
and the coolant pump pulley.
^ To install, tighten to 25 Nm (18 ft. lbs.).
5. Remove the bolts and the coolant pump.
^ To install, tighten to 25 Nm (18 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 2279
6. Remove and discard the coolant pump O-ring.
7. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These
tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all
traces of the old O-ring.
Clean the mating surfaces with a plastic scraper, if necessary, and metal surface prep. Follow the
directions on the packaging.
8. To install, reverse the removal procedure.
^ Install a new coolant pump O-ring. Lubricate the O-ring with clean engine coolant.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation
Catalytic Converter: Description and Operation
CATALYST AND EXHAUST SYSTEMS
Overview
V-Engines
In-Line Engines
The catalytic converter and exhaust Systems work together to control the release of harmful engine
exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N),
carbon dioxide (CO2) and water vapor (H2O) However, it also contains carbon monoxide (CO),
oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air
pollutants of CO, NOx, and HCs, and their emission into the atmosphere must be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated
oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the PCM.
For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency
Monitor. See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Monitors/Catalyst Efficiency Monitor
The number of HO2Ss used in the exhaust stream and the location of these sensors depend on the
vehicle emission certification level (LEV, LEV-II, ULEV, PZEV). On most vehicles only 2 HO2Ss are
used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for
primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor
catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each
engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for
primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off
catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long
term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Current PZEV
vehicles use only a 4-cylinder engine, so only the bank 1 HO2Ss are used.
Catalytic Converter
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2284
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst also enables 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 246°C to 302°C
(475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the
exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold
it lights off faster and reduces emissions more quickly than the catalyst located under the body.
Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that
catalyst.
Three-Way Catalyst (TWC) Conversion Efficiency
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. Deviations outside of this window greatly
decrease the conversion efficiency. For example a rich mixture decreases the HC and CO
conversion efficiency while a lean mixture decreases the NOx conversion efficiency.
Exhaust System
Typical Bank 1 Catalyst 2 HO2S Configuration
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2285
Typical Bank 1 Catalyst 3 HO2S Configuration
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. A HO2S is mounted on the front exhaust pipe
before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and
NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed
from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into
the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust
tailpipe.
On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold
(stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted
after the light-off catalyst.
Underbody Catalyst
The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line
with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming
a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific
vehicle, refer to Catalytic Converter, Exhaust System.
Three-Way Catalytic (TWC) Converter
The 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 3-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.
Heated Oxygen Sensor (HO2S)
The HO2Ss provide the powertrain control module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas.
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 also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Exhaust Manifold LH
Tighten the nuts in the sequence shown. Tighten to ...........................................................................
................................................................................................................ 25 Nm (18 ft. lbs.).
Exhaust Manifold RH
Tighten the nuts in the sequence shown. Tighten to ...........................................................................
................................................................................................................ 25 Nm (18 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications > Page 2289
Exhaust Manifold: Testing and Inspection
Exhaust Manifold Cleaning and Inspection
Special Tool(s)
1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the
gasket sealing surfaces.
2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an
exhaust manifold is serviced.
Using the special tool (or a precision straight edge) and a feeler gauge, check the exhaust manifold
sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 inch), install a new
exhaust manifold.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Detach the evaporative emission (EVAP) canister purge valve
from the bracket and position the valve aside.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2292
3. CAUTION: Do not allow the lower steering column shaft to rotate while it is disconnected from
the gear or the clockspring can be
damaged. If there is evidence that the lower steering column shaft has rotated, the clockspring
must be removed and recentered.
Remove the intermediate steering shaft pinch bolt and disconnect the intermediate steering shaft
from the lower steering column shaft.
4. Remove the 4 nuts and disconnect the dual converter Y-pipe from the exhaust manifolds. 5.
Remove the nuts and position the wiring harness bracket aside.
6. Remove the bolts and the LH exhaust manifold heat shield.
7. Remove and discard the pushpin. 8. Remove the 8 nuts, the LH exhaust manifold and the
gaskets.
^ Deflect the inner fender splash shield and remove the manifold between the splash shield and the
frame rail.
^ Discard the nuts and the gaskets.
9. Remove and discard the 8 LH exhaust manifold studs.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2293
Installation
1. Inspect the LH exhaust manifold gasket mating surfaces for flatness. 2. Install 8 new LH exhaust
manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).
3. Position the new gaskets, the LH exhaust manifold and install new nuts finger-tight.
^ Deflect the inner fender splash shield and install the exhaust manifold between the splash shield
and the frame rail.
4. Tighten the exhaust manifold nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
5. Position the inner fender splash shield and install a new pushpin.
6. Install the heat shield and the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
7. Position the wiring harness bracket and install the nuts.
^ Tighten to 10 Nm (89 inch lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2294
8. Connect the dual converter Y-pipe to the exhaust manifolds and install the 4 nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
9. Connect the intermediate steering shaft to the lower steering column shaft and install the pinch
bolt.
^ Tighten to 48 Nm (35 ft. lbs.).
10. Attach the EVAP canister purge valve to the bracket.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2295
Exhaust Manifold: Service and Repair Exhaust Manifold - RH
Exhaust Manifold - RH
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the 4 nuts and disconnect the dual converter Y-pipe
from the exhaust manifolds. 3. Remove the bolts and the RH exhaust manifold heat shield. 4.
Remove the pushpins and the splash shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > Exhaust Manifold - LH > Page 2296
5. Remove the 8 nuts, the RH exhaust manifold and the gaskets.
^ Discard the nuts and the gaskets.
6. Remove and discard the 8 RH exhaust manifold studs.
Installation
1. Inspect the exhaust manifold gasket mating surfaces for flatness. 2. Install 8 new RH exhaust
manifold studs.
^ Tighten to 12 Nm (9 ft. lbs.).
3. Position the new gaskets, the RH exhaust manifold and install new nuts finger-tight. 4. Tighten
the nuts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).
5. Position the splash shield and install the pushpins.
6. Position the heat shield and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).
7. Connect the dual converter Y-pipe to the exhaust manifolds and install the nuts.
^ Tighten to 40 Nm (30 ft. lbs.).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust Y-Pipe - Dual Catalytic Converter
Exhaust Pipe: Service and Repair Exhaust Y-Pipe - Dual Catalytic Converter
Exhaust Y-pipe - Dual Catalytic Converter
Material
Removal
WARNING: The normal operating temperature of the exhaust system is very high. Never work
around or attempt to repair any part of the exhaust system until it has cooled. Use special care
when working around the catalytic converter. The catalytic converter heats to a high temperature
after only a short period of engine operation. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause
deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger
bracket during vehicle operation. Use only water-based lubricants on the isolators.
NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same
part number as the original. Torque values must be used as specified during reassembly to make
sure of correct retention of exhaust components.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Using a suitable jack, support the exhaust system. 3.
Disconnect the heated oxygen sensor (HO2S) and the catalyst monitor sensors electrical
connectors. 4. Remove the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts
and gasket.
^ Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, nuts and gasket.
5. Remove the transmission support crossmember.
6. NOTE: RH side shown, LH similar.
Remove the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. ^
Discard the exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
7. Remove the exhaust Y-pipe dual catalytic converter.
Installation
1. NOTE: Apply anti-seize lubricant to the threads of the HO2S and catalyst monitor sensors.
If removed, install the HO2S and catalyst monitor sensors. ^
Tighten to 40 Nm (30 ft. lbs.).
2. NOTE: RH side shown, LH similar.
NOTE: Install new exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust Y-Pipe - Dual Catalytic Converter > Page 2301
Position the exhaust Y-pipe dual catalytic converter and loosely install the exhaust Y-pipe dual
catalytic converter-to-exhaust manifold nuts.
3. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket, bolts and
nuts.
Loosely install the exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket, bolts and
nuts.
4. Install the transmission support crossmember. 5. Align the exhaust system. 6. Connect the
HO2S and catalyst monitor sensors electrical connectors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust Y-Pipe - Dual Catalytic Converter > Page 2302
Exhaust Pipe: Service and Repair Tailpipe
Tailpipe
Removal
WARNING: The normal operating temperature of the exhaust system is very high. Never work
around or attempt to repair any part of the exhaust system until it has cooled. Use special care
when working around the catalytic converter. The catalytic converter heats to a high temperature
after only a short period of engine operation. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause
deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger
bracket during vehicle operation. Use only water-based lubricants on the isolators.
NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same
part number as the original. Torque values must be used as specified during reassembly to make
sure of correct retention of exhaust components.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair
2. NOTE: When the muffler assembly-to-tailpipe Torca(R) clamp is loosened, a new muffler
assembly-to-tailpipe Torca(R) clamp must be
installed.
Loosen the muffler assembly-to-tailpipe Torca(R) clamp.
3. Disconnect the rubber isolator and remove the tailpipe.
Installation
1. If reusing the tailpipe, install a new muffler assembly-to-tailpipe Torca(R) clamp. 2. Position the
tailpipe and connect the rubber isolator.
3. NOTE: Do not tighten the muffler assembly-to-tailpipe Torca(R) clamp until the exhaust system
has been aligned.
NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust.
Position the muffler assembly-to-tailpipe.
4. Align the exhaust system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair
Muffler: Service and Repair
Muffler
Removal
All vehicles
WARNING: The normal operating temperature of the exhaust system is very high. Never work
around or attempt to repair any part of the exhaust system until it has cooled. Use special care
when working around the catalytic converter. The catalytic converter heats to a high temperature
after only a short period of engine operation. Failure to follow these instructions may result in
personal injury.
CAUTION: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause
deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger
bracket during vehicle operation. Use only water-based lubricants on the isolators.
NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same
part number as the original. Torque values must be used as specified during reassembly to make
sure of correct retention of exhaust components.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Using a suitable jack, support the exhaust system.
4.0L Explorer Sport Trac
3. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is
serviced with 2 pieces.
NOTE: In order to remove the muffler assembly, you must cut the muffler inlet pipe.
Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the
muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the
service exhaust coupler nuts and separate the muffler inlet pipe. ^
Discard the service exhaust coupler.
4.6L Explorer Sport Trac
4. NOTE: The production muffler assembly is a one-piece design. The service muffler assembly is
serviced with 2 pieces.
NOTE: In order to remove the muffler assembly, you must cut the muffler inlet pipe.
Using a suitable exhaust cutter, cut the muffler inlet pipe between the first bend coming out of the
muffler and the next bend in line. If a service exhaust coupler is present at this point, loosen the
service exhaust coupler nuts and separate the muffler inlet pipe. ^
Discard the service exhaust coupler.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Page 2306
All vehicles
5. NOTE: When the muffler assembly-to-tailpipe Torca(R) clamp is loosened, a new muffler
assembly-to-tailpipe Torca(R) clamp must be
installed.
Loosen the muffler assembly-to-tailpipe Torca(R) clamp.
6. Remove the exhaust Y-pipe-dual catalytic converter-to-muffler assembly bolts, nuts and gasket.
^ Discard the exhaust Y-pipe-dual catalytic converter-to-muffler assembly bolts, nuts and gasket.
7. Disconnect the rubber isolators and remove the muffler assembly.
Installation
All vehicles
1. If reusing the tailpipe, install a new muffler assembly-to-tailpipe Torca(R) clamp. 2. Position the
muffler assembly and connect the rubber isolators.
3. NOTE: Do not tighten the muffler assembly-to-tailpipe Torca(R) clamp until the exhaust system
has been aligned.
NOTE: Using an abrasive pad, clean the muffler assembly-to-tailpipe surface area of any rust.
Position the muffler assembly-to-tailpipe.
Explorer Sport Trac
4. NOTE: Install a new muffler inlet pipe service coupler.
NOTE: Using an abrasive pad, clean the muffler inlet pipe service coupler surface area of any rust.
NOTE: If installing a service muffler kit, the coupling will be welded into position on the muffler inlet
pipe.
NOTE: The factory muffler inlet pipe will not have an alignment nub.
If reusing the factory muffler assembly, position the 2 halves of the muffler inlet pipe into the
service exhaust coupler and center the service exhaust coupler onto the cut joint on the muffler
inlet pipe. If installing a new service muffler kit, install the muffler inlet pipe coming out of the
muffler into the service exhaust coupler.
All Vehicles
5. NOTE: Install new exhaust Y-pipe-dual catalytic converter-to-muffler assembly gasket, bolts and
nuts.
Loosely install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly gasket, bolts and
nuts.
6. Align the exhaust system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver
Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver
Seat Module (DSM) > Page 2315
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration
information to a scan tool. This information must be downloaded into the new DSM after
installation.
1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors
and remove the DSM.
4. NOTE: Once the module is installed it is necessary to download the module configuration
information from the scan tool into the new module.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver
Seat Module (DSM) > Page 2316
Body Control Module: Service and Repair Smart Junction Box (Sjb)
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver
Seat Module (DSM) > Page 2317
Part 2
Removal
NOTE:
- The steps included in the SJB removal and installation procedure are critical to restoring the
vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered
in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure
monitoring system. The presence of these DTCs requires the installation procedures be followed in
order to clear the DTCs and enable normal SJB operations.
- Prior to the removal of the SJB, it is necessary to upload the module configuration information to
the diagnostic tool. This information must be downloaded to the new SJB after installation.
1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside.
3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for
the release lever to slide through the trim panel.
Remove the pushpin and the cowl side trim panel.
4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake
switch electrical connector. 6. Release the hood release cable pushpin from the parking brake
control bracket. 7. Release the harness clip from the parking brake cable housing.
8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the
instrument panel reinforcement.
Remove the 3 bolts and position the parking brake control assembly under the brake pedal.
9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the
instrument panel and may be broken if
any prying force is exerted in the lower area of the bezel.
Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the
instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside.
10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11.
Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the
instrument panel, remove the third SJB bolt.
13. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Driver
Seat Module (DSM) > Page 2318
(connected) position when installing.
Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the
SJB.
Installation
NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program
the RKE transmitters to the new SJB.
1. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
(connected) position when installing.
Position the SJB into the 2 locating pins and connect the 5 electrical connectors.
2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel
opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5.
Connect the 2 electrical connectors and install the headlight switch bezel assembly into the
instrument panel. 6. Position the parking brake control assembly and install the 3 bolts.
- Tighten to 20 Nm (15 lb-ft).
7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable
pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical
connector.
10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release
lever assembly and install the bolt.
12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the
release lever to slide through the trim panel.
Position the cowl side trim panel and install the pushpin.
13. Position the LH door opening weather seal. 14. Install the driver door scuff plate.
15. NOTE: When successful, this step provides the calibration necessary for SJB operation and
clears DTC B2477. The clearing of the DTC
indicates the calibration data has been successfully downloaded to the SJB.
Download the SJB configuration information from the diagnostic tool to the SJB.
16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing
of these DTCs indicates the SJB has recognized
the tire pressure sensors during the training procedure.
Train the tire pressure sensors.
17. Clear the DTCs.
18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing
mode, and to be sure there are no other concerns with
the newly programmed SJB.
Carry out the SJB on-demand self-test.
19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters
do not need to be reprogrammed to the vehicle.
However, if the module configuration upload/download is unsuccessful and as-built data must be
used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed
to the vehicle.
Program the RKE transmitters to the new SJB (if necessary).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The torque based ETC is a hardware and software strategy that delivers an engine output torque
(via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the
powertrain control module (PCM), and an accelerator pedal assembly to control the throttle
opening and engine torque. The ETC system replaces the standard cable operated accelerator
pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable camshaft
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: eliminate cruise control actuators
- eliminate idle air control (IAC) valve
- better airflow range
- packaging (no cable)
- more responsive powertrain at altitude and improved shift quality
It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on
the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble
codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC
motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position
signals are required for increased monitoring
reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and
the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal
operation the negative slope TP signal (TP1) is used by the control strategy as the indication of
throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage
- Signal return (ground)
- TP1 voltage with negative voltage slope (5-0 volts)
- TP2 voltage with positive voltage slope (0-5 volts)
Accelerator Pedal Position (APP) Sensors
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 2322
Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts)
- 2 signal return (ground) circuits
- APP1 voltage with negative voltage slope (5-0 volts)
- APP2 voltage with positive voltage slope (0-5 volts)
- APP3 voltage with positive voltage slope (0-5 volts)
3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
concern. The PCM determines if a signal is
incorrect by calculating where it should be, inferred from the other signals. A value is substituted for
an incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 2323
ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver
pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
ETC System Failure Mode And Effects Management (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 2324
ETC System Failure Mode And Effects Management (Part 2)
Since the IPC and the main controller share the same processor, they are subject to a number of
potential common failure modes. The E-Quizzer processor was added to redundantly monitor
selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC
and the main processor. If it determines that the IPC function is impaired in any way, it takes
appropriate failure mode and effects management (FMEM) actions.
Electronic Throttle Monitor Operation:
Electronic Throttle Monitor Operation (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 2325
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation > Page 2326
Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position.
- Greater than or equal to 4% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON,
engine OFF.
- Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential
ice buildup in the throttle body.
- Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard stop.
The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations
Engine Control Module: Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 2330
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions
Engine Control Module: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2333
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Symbols Part 2
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2338
Symbols Part 3
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2339
Symbols Part 4
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2340
Symbols Part 5
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Information and Instructions > Page 2341
Engine Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
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Information and Instructions > Page 2348
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Information and Instructions > Page 2349
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Information and Instructions > Page 2350
Engine Control Module: Connector Views
C175B (Part 1)
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C175B (Part 2)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2352
C175E (Part 1)
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Information and Instructions > Page 2353
C175E (Part 2)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2354
C175T (Part 1)
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Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2355
C175T (Part 2)
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair >
Powertrain Control Module (PCM)
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
Removal
All vehicles
1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys.
Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation procedure.
Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner.
All vehicles
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3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position
the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove
the bolts and the PCM.
Installation
All vehicles
1. Install the PCM and bolts.
- Tighten to 10 Nm (89 lb-in).
2. Connect the PCM electrical connectors.
3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front
wheel speed sensor electrical connector.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner.
All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps
of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system
(PATS). Carry out the Parameter Reset procedure.
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Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit (IC) internal to the powertrain control module
(PCM). The EEPROM contains the vehicle strategy including calibration information specific to the
vehicle, and is capable of being programmed or flashed repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan
tool manufacturer's instruction manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and needs programming. There are 2 procedures available. The first is an
automatic data transfer from the old PCM to the new PCM, and the second is manual data entry
into the new PCM.
Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by
using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored
data can then be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old module is damaged or incapable of communicating. Remove
and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter
programming, referring to the scan tool manufacturer's instruction manual. Make certain that all
parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile
equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF
may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center
for the information needed to manually update the VID block with the scan tool. Contact the center
only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury
technicians, contact your National Hotline or the Professional Technician Society (PTS) website for
As-Built data listed under the Service Publications Index. Non-Ford technicians use the
Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search
function to find the Module Programming or As-Built Data.
For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the
PTS website for quick Programmable Module data information by vehicle.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to Module Reprogramming on the scan tool.
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Page 2363
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C1450
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations
View 151-27 (Rear End)
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C4033
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Modules - Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 2373
Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal and Installation
1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM)
electrical connector. 3. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2377
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Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2381
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Relay > Component Information > Locations
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Modules - Ignition System > Ignition Relay > Component Information > Locations > Page 2386
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-12 (behind Dash Panel)
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Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2392
C2040
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Page 2393
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2397
C128
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Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2398
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
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Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
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Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1
View 151-7 (Engine, Front - 4.6L)
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft
Position Sensor 1 > Page 2405
View 151-7 (Engine, Front - 4.6L)
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C180
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Position Sensor > Page 2408
C1366
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Position Sensor > Page 2409
C1367
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2410
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
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2411
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
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Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
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C1064
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View 151-7 (Engine, Front - 4.6L)
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2421
Crankshaft Position Sensor: Diagrams
C101
C1120
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2422
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
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2423
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
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2424
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
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2428
C107
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2429
Engine Temperature Sensor: Description and Operation
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical CHT Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases., and the resistance
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.
The CHT sensor is installed in the 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 initiates a
fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern
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.
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2430
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
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View 151-19 (Right Rear)
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2434
Fuel Level Sensor: Diagrams
C434A
C434B
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Fuel Level Sensor: Description and Operation
FUEL LEVEL INPUT (FLI)
The FLI is a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
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Fuel Level Sensor: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
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Explorer Sport Trac (Part 2)
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Explorer/Mountaineer (Part 1)
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Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
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All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
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4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
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4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
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Fuel Tank Pressure Sensor: Description and Operation
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
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Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents a danger or 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 cause 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.
1. Remove the evaporative emission (EVAP) canister.
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2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor
electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick
connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank
pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the
evaporative emission system. See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection/Evaporative
Emission System Leak Test
8. Carry out the evaporative emission repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
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View 151-7 (Engine, Front - 4.6L)
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2451
C128
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2452
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type
MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance 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 air flow.
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The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described. One is located before the supercharger at the air cleaner for standard OBD/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 spark and to help determine charge air cooler (CAC) efficiency.
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C108
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Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
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Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Typical Manifold Absolute Pressure (MAP) Sensor
The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the
MAP sensor to measure how much exhaust gas is introduced into the intake manifold.
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View 151-8 (Engine, Rear - 4.6L)
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Page 2464
C104
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Page 2465
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical EOT Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance changes 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 sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control
gains and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM begins reducing power by disabling engine cylinders.
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Page 2466
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil.
- Install the drain plug and tighten to 26 Nm (19 lb-ft).
3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature
sensor.
- To install, tighten to 15 Nm (11 lb-ft).
5. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Fill the engine with clean engine oil.
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View 151-8 (Engine, Rear - 4.6L)
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Sensor (HO2S) #11 > Page 2471
View 151-8 (Engine, Rear - 4.6L)
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View 151-8 (Engine, Rear - 4.6L)
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View 151-8 (Engine, Rear - 4.6L)
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Sensor (HO2S) #22
C141
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C142
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C171
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C172
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Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a 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
a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by
providing the ground when the correct conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
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Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2482
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S)
is being serviced, remove the bolts and position the heat shield aside.
- To install, tighten to 20 Nm (15 lb-ft).
3. Disconnect the HO2S electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2483
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft).
5. To install, reverse the removal procedure.
- Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2484
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2485
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) > Page 2486
3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to
ease removal.
Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft).
4. To install, reverse the removal procedure.
- Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams
C121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and
Operation > Power Steering Pressure (PSP) Switch > Page 2492
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes 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 the transmission electronic pressure control (EPC) pressure during increased
engine load, for example, during parking maneuvers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Description and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Description and Operation > Page 2496
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2500
C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body (ETB) Position Sensor > Page 2503
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 2504
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 2505
Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2510
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2511
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2512
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2513
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2514
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2515
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2516
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2517
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2518
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2519
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2520
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2521
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2522
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2523
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2524
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2525
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2526
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 2527
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
> Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the 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 that is
generated.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor > Page 2532
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description
and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description
and Operation > Page 2537
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2542
C2040
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 2543
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2547
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2548
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2549
Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2550
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail
Pressure Transducer Sensor
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail
Pressure Transducer Sensor > Page 2555
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail
Pressure Transducer Sensor > Page 2556
View 151-5 (Engine, Front - 4.0L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor > Page 2559
C435
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation > Fuel Rail Pressure (FRP) Sensor
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation > Fuel Rail Pressure (FRP) Sensor > Page 2562
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation > Page 2563
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 2567
Fuel Temperature Sensor: Description and Operation
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 2568
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2572
C282
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2573
Inertia Fuel Shutoff Switch: Description and Operation
INERTIA FUEL SHUTOFF (IFS) SWITCH
Typical Inertia Fuel Shutoff (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shutoff 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's Literature for the location of the IFS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2574
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the
IFS switch
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 2578
C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body (ETB) Position Sensor > Page 2581
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 2582
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 2583
Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor
1 > Page 2589
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
C180
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 2592
C1366
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
> Page 2593
C1367
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2594
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2595
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2599
Crankshaft Position Sensor: Diagrams
C101
C1120
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2600
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2601
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2602
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 Switch Lock Cylinder: Service and Repair
IGNITION LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the ignition lock cylinder. 2. To install, reverse the removal procedure.
- Lubricate the ignition lock cylinder during installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams
C108
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 2610
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Fuel Pressure
Key on, engine off.................................................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
............................................................ 630-850 RPM
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Page 2622
Exploded View
Removal and Installation
NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector.
Vehicles equipped with a 4.0L (SOHC) engine
1. Detach the wiring harness retainer from the air cleaner outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Page 2623
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and
remove the air cleaner cover. 5. Remove the air cleaner element.
6. NOTE: Clean the inside of the air cleaner tray.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
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.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow
it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to
make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key
and wait 3 seconds to pressurize the fuel system.
Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame
scuff plate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications > Page 2631
Firing Order: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Number One Cylinder: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2640
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2641
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2642
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2643
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2644
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2645
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2646
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2647
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2648
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2649
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 2650
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions 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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > General Specifications
Spark Plug: Specifications General Specifications
Item.......................................................................................................................................................
..............................................................Specification
Spark plug gap (not adjustable)............................................................................................................
.....................................1.02-1.28 mm 0.040-0.050 in)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > General Specifications > Page 2653
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2654
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
....................................................................... PZT1F
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2655
Spark Plug: Testing and Inspection
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2656
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2657
Spark Plug: Service and Repair
SPARK PLUGS
Exploded View
Removal and Installation
1. Disconnect the ignition coil electrical connectors. 2. Remove the ignition coil bolts.
- To install, tighten to 5 Nm (44 lb-in).
3. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease
removal.
Remove the ignition coils.
4. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is re-used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
5. CAUTION: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark
plug is adjusted. Install a new spark
plug if the gap is out of specification.
Inspect the spark plugs. Install new spark plugs as necessary.
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2658
6. To install, reverse the removal procedure.
- Apply a light film of brake caliper grease to the inside of the coil boots before installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2662
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 5 compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test - Test Results The indicated compression pressures are considered within
specification if the lowest reading cylinder is at least 75% of the highest reading. Refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart
If one or more cylinders read 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 2 adjacent cylinders indicate low
compression pressures and squirting oil on each piston does not increase compression, the head
gasket may be
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2663
leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is at least 75% of the highest reading.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 2668
C2040
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor
> Component Information > Locations > Page 2669
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2673
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2674
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2675
Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Locations > Page 2676
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2680
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2681
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type
MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance 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 air flow.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Locations > Page 2682
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described. One is located before the supercharger at the air cleaner for standard OBD/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 spark and to help determine charge air cooler (CAC) efficiency.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service and Repair > Driver Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2688
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration
information to a scan tool. This information must be downloaded into the new DSM after
installation.
1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors
and remove the DSM.
4. NOTE: Once the module is installed it is necessary to download the module configuration
information from the scan tool into the new module.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2689
Body Control Module: Service and Repair Smart Junction Box (Sjb)
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2690
Part 2
Removal
NOTE:
- The steps included in the SJB removal and installation procedure are critical to restoring the
vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered
in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure
monitoring system. The presence of these DTCs requires the installation procedures be followed in
order to clear the DTCs and enable normal SJB operations.
- Prior to the removal of the SJB, it is necessary to upload the module configuration information to
the diagnostic tool. This information must be downloaded to the new SJB after installation.
1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside.
3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for
the release lever to slide through the trim panel.
Remove the pushpin and the cowl side trim panel.
4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake
switch electrical connector. 6. Release the hood release cable pushpin from the parking brake
control bracket. 7. Release the harness clip from the parking brake cable housing.
8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the
instrument panel reinforcement.
Remove the 3 bolts and position the parking brake control assembly under the brake pedal.
9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the
instrument panel and may be broken if
any prying force is exerted in the lower area of the bezel.
Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the
instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside.
10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11.
Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the
instrument panel, remove the third SJB bolt.
13. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service and Repair > Driver Seat Module (DSM) > Page 2691
(connected) position when installing.
Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the
SJB.
Installation
NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program
the RKE transmitters to the new SJB.
1. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
(connected) position when installing.
Position the SJB into the 2 locating pins and connect the 5 electrical connectors.
2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel
opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5.
Connect the 2 electrical connectors and install the headlight switch bezel assembly into the
instrument panel. 6. Position the parking brake control assembly and install the 3 bolts.
- Tighten to 20 Nm (15 lb-ft).
7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable
pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical
connector.
10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release
lever assembly and install the bolt.
12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the
release lever to slide through the trim panel.
Position the cowl side trim panel and install the pushpin.
13. Position the LH door opening weather seal. 14. Install the driver door scuff plate.
15. NOTE: When successful, this step provides the calibration necessary for SJB operation and
clears DTC B2477. The clearing of the DTC
indicates the calibration data has been successfully downloaded to the SJB.
Download the SJB configuration information from the diagnostic tool to the SJB.
16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing
of these DTCs indicates the SJB has recognized
the tire pressure sensors during the training procedure.
Train the tire pressure sensors.
17. Clear the DTCs.
18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing
mode, and to be sure there are no other concerns with
the newly programmed SJB.
Carry out the SJB on-demand self-test.
19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters
do not need to be reprogrammed to the vehicle.
However, if the module configuration upload/download is unsuccessful and as-built data must be
used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed
to the vehicle.
Program the RKE transmitters to the new SJB (if necessary).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Locations > Page 2695
C278
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 2698
Brake Signal: Description and Operation Brake Pedal Switch (BPS) Brake Deactivator Switch
BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Camshaft Position Sensor 1 > Page 2703
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor
C180
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor > Page 2706
C1366
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Camshaft Position Sensor > Page 2707
C1367
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2708
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2709
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component
Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Diagrams
C1064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2719
Crankshaft Position Sensor: Diagrams
C101
C1120
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2720
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2721
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 2722
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2728
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2729
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2730
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2731
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2732
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2733
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2734
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2735
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2736
Data Link Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2737
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2738
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2739
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2740
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2741
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2742
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2743
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2744
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 2745
C251
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 2749
C1368
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Component Information > Locations > Page 2750
Electronic Throttle Actuator: Description and Operation
ELECTRONIC THROTTLE ACTUATOR CONTROL (TAC)
The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). The gear ratio from the
motor to the throttle plate shaft is 17:1. There are 2 designs for the TAC, parallel and in-series. The
parallel design has the motor under the bore parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing. Two springs
are used; one is used to close the throttle (main spring) and the other is in a plunger assembly that
results in a default angle when no power is applied. The force of the plunger spring is 2 times
stronger than the main spring. The default angle is usually set to result in a top vehicle speed of 48
km/h (30 mph). Typically this throttle angle is 7 to 8 degree from the hard stop angle. The closed
throttle plate hard stop is used to prevent the throttle from binding in the bore (~ 0.75 degree). This
hard stop setting is not adjustable and is set to result in less airflow than the minimum engine
airflow required at idle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The torque based ETC is a hardware and software strategy that delivers an engine output torque
(via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the
powertrain control module (PCM), and an accelerator pedal assembly to control the throttle
opening and engine torque. The ETC system replaces the standard cable operated accelerator
pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable camshaft
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: eliminate cruise control actuators
- eliminate idle air control (IAC) valve
- better airflow range
- packaging (no cable)
- more responsive powertrain at altitude and improved shift quality
It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on
the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble
codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC
motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position
signals are required for increased monitoring
reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and
the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal
operation the negative slope TP signal (TP1) is used by the control strategy as the indication of
throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage
- Signal return (ground)
- TP1 voltage with negative voltage slope (5-0 volts)
- TP2 voltage with positive voltage slope (0-5 volts)
Accelerator Pedal Position (APP) Sensors
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2754
Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts)
- 2 signal return (ground) circuits
- APP1 voltage with negative voltage slope (5-0 volts)
- APP2 voltage with positive voltage slope (0-5 volts)
- APP3 voltage with positive voltage slope (0-5 volts)
3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
concern. The PCM determines if a signal is
incorrect by calculating where it should be, inferred from the other signals. A value is substituted for
an incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2755
ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver
pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
ETC System Failure Mode And Effects Management (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2756
ETC System Failure Mode And Effects Management (Part 2)
Since the IPC and the main controller share the same processor, they are subject to a number of
potential common failure modes. The E-Quizzer processor was added to redundantly monitor
selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC
and the main processor. If it determines that the IPC function is impaired in any way, it takes
appropriate failure mode and effects management (FMEM) actions.
Electronic Throttle Monitor Operation:
Electronic Throttle Monitor Operation (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2757
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
> Component Information > Description and Operation > Page 2758
Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position.
- Greater than or equal to 4% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON,
engine OFF.
- Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential
ice buildup in the throttle body.
- Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard stop.
The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations
Engine Control Module: Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Locations > Page 2762
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Engine Control Module: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2765
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2766
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2767
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2768
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2769
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2770
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2771
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2772
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2773
Engine Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2774
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2775
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2776
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2777
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2778
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2779
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2780
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2781
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2782
Engine Control Module: Connector Views
C175B (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2783
C175B (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2784
C175E (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2785
C175E (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2786
C175T (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2787
C175T (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Powertrain Control Module (PCM)
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
Removal
All vehicles
1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys.
Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation procedure.
Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 2790
3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position
the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove
the bolts and the PCM.
Installation
All vehicles
1. Install the PCM and bolts.
- Tighten to 10 Nm (89 lb-in).
2. Connect the PCM electrical connectors.
3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front
wheel speed sensor electrical connector.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner.
All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps
of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system
(PATS). Carry out the Parameter Reset procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Service and Repair > Powertrain Control Module (PCM) > Page 2791
Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit (IC) internal to the powertrain control module
(PCM). The EEPROM contains the vehicle strategy including calibration information specific to the
vehicle, and is capable of being programmed or flashed repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan
tool manufacturer's instruction manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and needs programming. There are 2 procedures available. The first is an
automatic data transfer from the old PCM to the new PCM, and the second is manual data entry
into the new PCM.
Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by
using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored
data can then be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old module is damaged or incapable of communicating. Remove
and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter
programming, referring to the scan tool manufacturer's instruction manual. Make certain that all
parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile
equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF
may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center
for the information needed to manually update the VID block with the scan tool. Contact the center
only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury
technicians, contact your National Hotline or the Professional Technician Society (PTS) website for
As-Built data listed under the Service Publications Index. Non-Ford technicians use the
Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search
function to find the Module Programming or As-Built Data.
For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the
PTS website for quick Programmable Module data information by vehicle.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to Module Reprogramming on the scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 2795
C107
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 2796
Engine Temperature Sensor: Description and Operation
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical CHT Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases., and the resistance
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.
The CHT sensor is installed in the 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 initiates a
fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern
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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Locations > Page 2797
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2801
Fuel Level Sensor: Diagrams
C434A
C434B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2802
Fuel Level Sensor: Description and Operation
FUEL LEVEL INPUT (FLI)
The FLI is a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2803
Fuel Level Sensor: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2804
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2805
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2806
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2807
All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2808
4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Locations > Page 2809
4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation
Fuel Tank Pressure Sensor: Description and Operation
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation > Page 2813
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents a danger or 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 cause 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.
1. Remove the evaporative emission (EVAP) canister.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Description and Operation > Page 2814
2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor
electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick
connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank
pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the
evaporative emission system. See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection/Evaporative
Emission System Leak Test
8. Carry out the evaporative emission repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation
Idle Speed/Throttle Actuator - Electronic: Description and Operation
IDLE AIR CONTROL (IAC) VALVE
NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are
normally open and others are normally closed. Some IAC valves require engine vacuum to
operate.
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
The PCM uses the IAC valve assembly to control:
- no touch start
- cold engine fast idle for rapid warm-up
- idle (corrects for engine load)
- stumble or stalling on deceleration (provides a dashpot function)
- over-temperature idle boost
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2822
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2823
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2824
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions > Page 2825
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Symbols Part 2
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Symbols Part 3
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Symbols Part 4
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Symbols Part 5
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Information Bus: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Information Bus: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
14-1
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14-2
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14-5
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
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Information Bus: Description and Operation
COMMUNICATIONS NETWORK
Vehicle communication utilizes both medium and high speed controller area network (CAN)
communications. CAN is used for many modules to communicate with each other on a common
network. CAN in-vehicle networking, is a method for transferring data among distributed electronic
modules via a serial data bus. Without serial networking, intermodule communication requires
dedicated, point to point wiring resulting in bulky, expensive, complex, and difficult to install wiring
harnesses. Applying a serial data network reduces the number of wires combining the signals on a
single network. Information is sent to the individual control modules that control each function.
The vehicle has 2 module communication networks:
- Medium speed (MS) CAN
- High speed (HS) CAN
Both networks are connected to the data link connector (DLC). This makes diagnosis and testing of
these systems easier by allowing one scan tool to be able to diagnose and control any module on
both networks from one connector. The DLC can be found under the instrument panel between the
steering column and the audio unit.
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Network Topology
MS-CAN Network Operation
The MS-CAN network communicates using bussed messages. The MS-CAN has an unshielded
twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool communication,
this network allows sharing of information between all modules on the network.
The MS-CAN is a medium speed communication network used for the following modules: SJB
- Audio unit
- Instrument cluster
- DSM (if equipped)
- DVD player (if equipped)
- EATC module (if equipped)
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- Parking aid module (if equipped)
- Satellite audio receiver (if equipped)
- Power running board module (if equipped)
HS-CAN Network Operation
The HS-CAN network communicates using bussed messages. The HS-CAN network uses an
unshielded twisted pair cable, data bus (+) and data bus (-) circuits. In addition to scan tool
communication, this network allows sharing of information between all modules on the network.
The HS-CAN is a high speed communication network used for the following modules: PCM
- TCM (if equipped)
- RCM
- ABS module
- Instrument cluster
- Occupant classification sensor module
- 4WD control module (if equipped)
Network Termination
The CAN network uses a network termination circuit to improve communication reliability. The
network termination of the CAN bus takes place inside the termination modules by termination
resistors. Termination modules are located at either end of the bus network. As network messages
are broadcast in the form of voltage signals, the network voltage signals are stabilized by the
termination resistors. Each termination module has a 120ohm resistor across the positive and
negative bus connection in the termination module. With 2 termination modules on each network,
and the 120 ohm resistors located in a parallel circuit configuration, the total network impedance, or
total resistance is 60 ohms.
Network termination improves bus message reliability by: stabilizing bus voltage.
- eliminating electrical interference.
Gateway Module
The instrument cluster is the gateway module, translating HS-CAN to MS-CAN and vice versa. This
information allows a message to be distributed throughout both networks. The instrument cluster is
the only module on this vehicle that has this ability.
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Information Bus: Initial Inspection and Diagnostic Overview
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical
damage.
VISUAL INSPECTION CHART
Electrical Battery junction box (BJB) fuse(s): 3 (50A) (no communication with smart junction box [SJB])
- 6 (40A) (no communication with anti-lock brake system [ABS] module)
- 19 (30A) (no communication with power running board module)
- 23 (20A) (no communication with four wheel drive [4WD] control module)
- 24 (10A) (no communication with powertrain control module [PCM])
- 26 (20A) (no communication with 4WD control module)
- 27 (20A) (no communication with transmission control module [TCM])
- 33 (30A) (no communication with ABS module)
- 39 (15A) (no communication with PCM)
- 41 (15A) (no communication with satellite radio receiver, digital versatile disc [DVD])
- Smart junction box (SJB) fuse(s): 1 (20A) (no communication with driver seat module [DSM])
- 2 (5A) (no communication with SJB)
- 3 (20A) (no communication with audio unit)
- 4 (20A) (no power to scan tool)
- 8 (15A) (no communication with instrument cluster)
- 9 (2A) (no communication with TCM)
- 12 (5A) (no communication with audio unit)
- 17 (10A) (no communication with restraints control module [RCM], occupant classification sensor
module)
- 18 (10A) (no communication with ABS module, 4WD control module, parking aid module)
- 20 (10A) (no communication with electronic automatic temperature control [EATC]) module
- 24 (10A) (no communication with instrument cluster)
- 28 (10A) (no communication with EATC module)
- Data link connector (DLC)
- Wiring harness
- Circuitry
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
4. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the DLC.
NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground from
the DLC are provided to the VCM.
If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle.
- Check the scan tool connection to the VCM.
- GO to Pinpoint Test R, to diagnose no power to the scan tool. See: Pinpoint Tests/Test R: No
Power to the Scan Tool
5. NOTE: During the network test, the scan tool will first attempt to communicate with the PCM,
after establishing communication with the PCM,
the scan tool will then attempt to communicate with all other modules on the vehicle.
Carry out the network test: If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step
6.
- If the network test fails, GO to Symptom Chart to identify the module not communicating. See:
Symptom Related Diagnostic Procedures
6. If the DTCs retrieved are related to the concern, go to the Communication Network Diagnostic
Trouble Code (DTC) Chart. For all other DTCs,
refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble
Code Descriptions/Module Communications Network
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Principles of Operation
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PRINCIPLES OF OPERATION
Vehicle communication utilizes both medium and high speed controller area network (CAN)
communications. CAN is a method for transferring data among distributed electronic modules via a
serial data bus.
The vehicle is equipped with 2 module communication networks:
- Medium speed (MS) CAN
- High speed (HS) CAN
MS-CAN
The MS-CAN is a medium speed communication network that uses an unshielded twisted pair
cable of data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to
approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the
data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is
reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be
sent over the network CAN circuits allowing multiple modules to communicate with each other. The
MS-CAN network will not communicate while certain faults are present, but will operate with
diminished performance with other faults present. The MS-CAN network may remain operational
when 1 of the 2 termination resistors are not present.
The MS-CAN network operates at a maximum data transfer speed of 125 Kbps for bus messages
and designed for general information transfer. The network will remain operational, but at a
degraded level, when certain circuit faults are present.
The following modules are on the MS-CAN network: Audio unit
- Instrument cluster
- Smart junction box (SJB)
- Parking aid module (if equipped)
- Driver seat module (if equipped
- Satellite radio receiver (if equipped)
- Power running board module (if equipped)
- Digital versatile disc (DVD) player (if equipped)
- Electronic automatic temperature control (EATC) module (if equipped)
MS-CAN Network Communication Fault Chart
The fault chart describes the specific MS-CAN network failures and their resulting symptom:
HS-CAN
The HS-CAN is a high speed communication network that uses an unshielded twisted pair cable of
data (+) and data (-) circuits. The data (+) and the data (-) circuits are each regulated to
approximately 2.5 volts during neutral or rested network traffic. As bus messages are sent on the
data (+) circuit, voltage is increased by approximately 1.0 volt. Inversely, the data (-) circuit is
reduced by approximately 1.0 volt when a bus message is sent. Multiple bus messages can be
sent over the network CAN circuits allowing multiple modules to communicate with each other. The
HS-CAN network will not communicate while certain faults are present, but will operate with
diminished performance with other faults present. The HS-CAN bus may remain operational when
1 of the 2 termination resistors are not present. The HS-CAN network operates at a maximum data
transfer speed of 500 Kbps and is designed for real time information transfer and control. The
network will remain operational, but at a degraded level, when certain circuit faults are present.
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The following modules are on the HS-CAN network: Instrument cluster
- Powertrain control module (PCM)
- Anti-lock brake system (ABS) module
- Restraints control module (RCM)
- Occupant classification sensor module
- Transmission control module (TCM) (if equipped)
- Four wheel drive (4WD) control module (if equipped)
HS-CAN Network Communication Fault Chart
The fault chart describes the specific HS-CAN network failures and their resulting symptom:
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CAN Network Module Communication Message Chart (Part 1)
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CAN Network Module Communication Message Chart (Part 2)
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CAN Network Module Communication Message Chart (Part 3)
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CAN Network Module Communication Message Chart (Part 4)
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CAN Network Module Communication Message Chart (Part 5)
The chart describes the specific CAN network messages broadcast by each module, and the
module(s) that receive the message:
Inspection and Verification
INSPECTION AND VERIFICATION
This provides step-by-step module configuration procedures. Carry out the programmable module
installation (PMI) procedure when another directs to carry out configuration or when DTCs from the
list are present.
Principles of Operation
PRINCIPLES OF OPERATION
Configurable modules accommodate a variety of vehicle options, eliminating the need for many
unique modules for one vehicle line. These modules must be configured when replaced as part of a
repair procedure.
Configurable modules should not be exchanged between vehicles since the settings are unique to
each vehicle. Failure to configure a new module may result in improper operation and/or any of the
following DTCs setting:
- B2477 and/or B2141 - sets when a body/chassis module is not configured.
- B2900 - sets when there is a VIN mismatch between the module with the B2900 and the PCM.
Either the PCM or the body module stored VIN
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may be incorrect.
- P0602, P0605 and/or P1639 - sets when the powertrain control module (PCM) vehicle
identification (VID) block is not configured or is configured incorrectly.
- U0300 and/or U0301 - sets when the configuration between 2 or more modules do not match.
- U2050 and/or U2051 - sets when a valid strategy/calibration is not present.
The following are the 3 different methods of configuration:
- Programmable module installation (PMI)
- Module reprogramming ("flashing")
- Programmable parameters
Some modules do not support all 3 methods.
Definition of Terms
The following are definitions of configuration terms:
Programmable Module Installation (PMI) PMI is a scan tool process which configures settings in a
new module. Data used for the PMI process is automatically downloaded from the original module
and stored when a scan tool session is started. If this data cannot be retrieved from the module
being replaced, the scan tool may prompt for As-Built data entry or display a list of parameter
values that need to be manually selected. Some modules are reprogrammed during PMI when a
strategy/calibration update is available.
NOTE: A module must be able to communicate with the scan tool in order to carry out PMI. It is
important that the scan tool identifies the vehicle and obtains configuration data prior to removing
any modules.
To carry out PMI, refer to Programmable Module Installation.
Module Reprogramming Module reprogramming (also referred to as "flashing") is a scan tool
process which updates the strategy/calibration in a module. Module reprogramming is
automatically carried out during PMI when a later strategy/calibration is available. Reprogramming
a module with the same level of software will not improve module operation or repair a hardware
failure.
NOTE: Module reprogramming should be limited to circumstances where a published Technical Service
Bulletin (TSB) procedure recommends doing so.
- A module cannot communicate with other modules on the communication network while being
reprogrammed. Clear any network communication DTCs which may have been set in other
modules during reprogramming.
Programmable Parameters Programmable parameters are customer preference items that may be
modified by the dealer via scan tool or in some cases modified by the customer following a
procedure listed in the vehicle Owner's Literature. While many configuration options may exist for a
module, only a few of these options are programmable parameters.
Adaptive Learning and Calibration
Some modules require a separate learning procedure be carried out if replaced as part of a repair
procedure. For adaptive learning and calibration instructions, refer to the specific module removal
and installation procedures.
Vehicle Identification (VID) Block
Some PCMs contain a memory area called a vehicle identification (VID) block. The PCM VID block
commonly stores powertrain configuration items such as VIN, tire size, axle ratio, and whether or
not the vehicle is equipped with speed control.
As-Built Data
As-Built data is a VIN specific module configuration record. During vehicle build, the configuration
from all modules is downloaded and stored in the As-Built database. As Built data will not reflect
customer preference items that have been changed from the default state. These items will need to
be changed using programmable parameters after the module is configured.
NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This
data may be accessed from the technician service publication website.
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Body/Chassis Module Addresses for As-Built Entry
The chart lists body/chassis module As-Built data addresses.
Module Configuration And Parameter Chart (Part 1)
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Module Configuration And Parameter Chart (Part 2)
The chart describes specific module programming information.
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Information Bus: Diagnostic Trouble Code Descriptions
U0073-U0140
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U0154-U1900
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U1900-U2471
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U2472-U2511
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B2477-B2900 / P0602-P1639 / U0300-U2050
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U2051
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Information Bus: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
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Symptom Chart (Part 2)
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Information Bus: Pinpoint Tests
Test A: The Powertrain Control Module (PCM) Does Not Respond to the Scan Tool
PINPOINT TEST A: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO
THE SCAN TOOL
A1-A2
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A3-A4
Normal Operation
The PCM communicates with the scan tool through the high speed controller area network
(HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the
network connection to the PCM. The PCM shares the HS-CAN network with the transmission
control module (TCM) (if equipped), the anti-lock brake system (ABS) module, the restraints control
module (RCM), the four wheel drive (4WD) control module (if equipped), the occupant classification
sensor module and the instrument cluster.
Possible Causes
- Circuit VDB04 (WH/BU) open (HS-CAN +)
- Circuit VDB05 (WH) open (HS-CAN -)
- PCM
Test B: The Transmission Control Module (TCM) Does Not Respond to the Scan Tool
PINPOINT TEST B: THE TRANSMISSION CONTROL MODULE (TCM) DOES NOT RESPOND
TO THE SCAN TOOL
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2867
B1-B2
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2868
B3-B4
Normal Operation
The 6R60 transmission utilizes a TCM to control transmission functions. The TCM communicates
with the scan tool through the high speed controller area network (HS-CAN). Circuits VDB04
(WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the network connection to the TCM.
The TCM shares the HS-CAN network with the powertrain control module (PCM), the anti-lock
brake system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD)
control module (if equipped), the occupant classification sensor module and the instrument cluster.
Voltage for the TCM is provided by circuits SBB27 (BU/RD) and CE517 (BU/GN). Circuit GD113
(BK/YE) provides ground.
Possible Causes
- Fuse
- Circuit CE517 (BU/GN) open
- Circuit GD113 (BK/YE) open
- Circuit SBB27 (BU/RD) open
- Circuit VDB04 (WH/BU) open (HS-CAN +)
- Circuit VDB05 (WH) open (HS-CAN -)
- TCM
Test C: The Anti-Lock Brake System (ABS) Module Does Not Respond to the Scan Tool
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2869
PINPOINT TEST C: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND
TO THE SCAN TOOL
C1-C2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2870
C3-C4
Normal Operation
The ABS module communicates with the scan tool through the high speed controller area network
(HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the
network connection to the ABS module. The ABS module shares the HS-CAN network with the
powertrain control module (PCM), the transmission control module (TCM) (if equipped), the
restraints control module (RCM), the four wheel drive (4WD) control module (if equipped), the
occupant classification sensor module and the instrument cluster. Voltage for the ABS module is
provided by circuits CBP18 (GY/OG), SBB06 (BN/RD) and SBB33 (RD). Ground is provided by
circuit GD120 (BK/GN).
Possible Causes
- Fuse
- Circuit CBP18 (GY/OG) open
- Circuit SBB06 (BN/RD) open
- Circuit SBB33 (RD) open
- Circuit GD120 (BK/GN) open
- Circuit VDB04 (WH/BU) open (HS-CAN +)
- Circuit VDB05 (WH) open (HS-CAN -)
- ABS module
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2871
Test D: The Restraints Control Module (RCM) Does Not Respond to the Scan Tool
PINPOINT TEST D: THE RESTRAINTS CONTROL MODULE (RCM) DOES NOT RESPOND TO
THE SCAN TOOL
D1-D2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2872
D2-D4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2873
D4-D5
Normal Operation
The RCM communicates with the scan tool through the high speed controller area network
(HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide the
network connection to the RCM. The RCM shares the HS-CAN network with the powertrain control
module (PCM), the transmission control module (TCM) (if equipped), the anti-lock brake system
(ABS) module, the four wheel drive (4WD) control module (if equipped), the occupant classification
sensor module and the instrument cluster. Voltage for the RCM is provided by circuit CBP17
(BN/GN), and the RCM is case grounded.
Possible Causes
- Fuse
- Circuit CBP17 (BN/GN) open
- Circuit VDB04 (WH/BU) open (HS-CAN +)
- Circuit VDB05 (WH) open (HS-CAN -)
- Case ground open
- RCM
Test E: The Four Wheel Drive (4WD) Control Module Does Not Respond to the Scan Tool
PINPOINT TEST E: THE FOUR WHEEL DRIVE (4WD) CONTROL MODULE DOES NOT
RESPOND TO THE SCAN TOOL
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2874
E1-E3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2875
E3-E4
Normal Operation
The 4WD control module communicates with the scan tool through the high speed controller area
network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide
the network connection to the 4WD control module. The 4WD control module shares the HS-CAN
with powertrain control module (PCM), the transmission control module (TCM) (if equipped), the
anti-lock brake system (ABS) module, the restraints control module (RCM), the occupant
classification sensor module and the instrument cluster. Voltage is supplied by circuits CBP18
(GY/OG), SBB23 (RD/WH) and SBB26 (RD/BK). Ground is supplied by circuits GD138 (BK/WH)
and GD145 (BK/BU).
Possible Causes
- Fuse
- Circuit CBP18 (GY/OG) open
- Circuit GD138 (BK/WH) open
- Circuit GD145 (BK/BU) open
- Circuit SBB23 (RD/WH) open
- Circuit SBB26 (RD/BK) open
- Circuit VDB04 (WH/BU) open (HS-CAN +)
- Circuit VDB05 (WH) open (HS-CAN -)
- 4WD control module
Test F: The Occupant Classification Sensor Module Does Not Respond to the Scan Tool
PINPOINT TEST F: THE OCCUPANT CLASSIFICATION SENSOR MODULE DOES NOT
RESPOND TO THE SCAN TOOL
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2876
F1-F2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2877
F2-F3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2878
F4
Normal Operation
The occupant classification sensor module communicates with the scan tool through the high
speed controller area network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH)
(HS-CAN -) provide the network connection to the occupant classification sensor module. The
occupant classification sensor module shares the HS-CAN with the powertrain control module
(PCM), the transmission control module (TCM) (if equipped), the anti-lock brake system (ABS)
module, the restraints control module (RCM), the four wheel drive (4WD) control module (if
equipped) and the instrument cluster. Voltage to the occupant classification sensor module is
supplied by circuit CBP17 (BN/GN). Ground is supplied by circuit GD145 (BK/BU).
Possible Causes
- Fuse
- Circuit CBP17 (BN/GN) open
- Circuit GD145 (BK/BU) open
- Circuit VDB04 (WH/BU) open (HS-CAN +)
- Circuit VDB05 (WH) open (HS-CAN -)
- Occupant classification sensor module
Test G: The Instrument Cluster Does Not Respond to the Scan Tool
PINPOINT TEST G: THE INSTRUMENT CLUSTER DOES NOT RESPOND TO THE SCAN TOOL
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2879
G1-G3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2880
G3-G4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2881
G5
Normal Operation
The instrument cluster communicates with the scan tool through the high speed controller area
network (HS-CAN). Circuits VDB04 (WH/BU) (HS-CAN +) and VDB05 (WH) (HS-CAN -) provide
the HS-CAN network connection to the instrument cluster and circuits VDB06 (GY/OG) (MS-CAN
+) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN network connection to the instrument
cluster. The instrument cluster shares the HS-CAN network with the powertrain control module
(PCM), the transmission control module (TCM) (if equipped), the anti-lock brake system (ABS)
module, the restraint control module (RCM), the four wheel drive (4WD) control module (if
equipped) and the occupant classification sensor module. The instrument cluster shares the
MS-CAN network with the smart junction box (SJB), the electronic automatic temperature control
(EATC) module (if equipped), the audio unit, the satellite radio receiver (if equipped), the driver
seat module (DSM) (if equipped), the parking aid module (if equipped), the power running board
module (if equipped) and the digital versatile disc (DVD) player (if equipped). Voltage for the
instrument cluster is provided by circuits CDC34 (WH/OG) and SBP24 (VT/RD). Circuit GD145
(BK/BU) provides ground.
Possible Causes
- Fuse
- Circuit CDC34 (WH/OG) open
- Circuit GD145 (BK/BU) open
- Circuit SBP24 (VT/RD) open
- Circuit VDB04 (WH/BU) open (HS-CAN +)
- Circuit VDB05 (WH) open (HS-CAN -)
- Instrument cluster
Test H: The Smart Junction Box (SJB) Does Not Respond to the Scan Tool
PINPOINT TEST H: THE SMART JUNCTION BOX (SJB) DOES NOT RESPOND TO THE SCAN
TOOL
H1
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H1-H3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2883
H3-H4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2884
H5
Normal Operation
The SJB communicates with the scan tool through the medium speed controller area network
(MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the
network connection to the SJB. The SJB shares the MS-CAN network with the instrument cluster,
the electronic automatic temperature control (EATC) module (if equipped), the audio unit, the
satellite radio receiver (if equipped), the driver seat module (DSM) (if equipped), the parking aid
module (if equipped), the power running board module (if equipped), and the digital versatile disc
(DVD) player (if equipped). Voltage for the SJB is provided by circuit SBB03 (BU/RD). Circuit
GD108 (BK/VT) provides ground.
Possible Causes
- Fuse
- Circuit SBB03 (BU/RD) open
- Circuit GD108 (BK/VT) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- SJB
Test I: The Electronic Automatic Temperature Control (EATC) Module Does Not Respond to the
Scan Tool
PINPOINT TEST I: THE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC)
MODULE DOES NOT RESPOND TO THE SCAN TOOL.
I1
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2885
I1-I2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2886
I3-I4
Normal Operation
The EATC module communicates with the scan tool through the medium speed controller area
network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -)
provide the network connection to the EATC module. The EATC module shares the MS-CAN
network with the instrument cluster, the smart junction box (SJB), the audio unit, the satellite radio
receiver (if equipped), the digital versatile disc (DVD) player (if equipped), the driver seat module
(DSM) (if equipped), the power running board module (if equipped) and the parking aid module (if
equipped). Voltage for the EATC module is provided by circuits CBP20 (YE/VT) and SBP28
(GN/RD). Circuit GD145 (BK/BU) provides ground.
Possible Causes
- Fuse
- Circuit CBP20 (YE/VT) open
- Circuit GD145 (BK/BU) open
- Circuit SBP28 (GN/RD) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- EATC module
Test J: The Audio Unit Does Not Respond to the Scan Tool
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2887
PINPOINT TEST J: THE AUDIO UNIT DOES NOT RESPOND TO THE SCAN TOOL
J1-J2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2888
J2-J3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2889
J4
Normal Operation
Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network
connection to the audio unit. The audio unit shares the MS-CAN network with the instrument
cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module
(if equipped), the satellite radio receiver (if equipped), the digital versatile disc (DVD) player, the
driver seat module (DSM) (if equipped), the power running board module (if equipped) and the
parking aid module (if equipped). Voltage for the audio unit is provided by circuits CBP12 (GN/WH)
and SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground.
Possible Causes
- Fuse
- Circuit CBP12 (GN/WH) open
- Circuit GD114 (BK/BU) open
- Circuit SBP03 (BU/RD) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- Audio unit
Test K: The Satellite Radio Receiver Does Not Respond to the Scan Tool
PINPOINT TEST K: THE SATELLITE RADIO RECEIVER DOES NOT RESPOND TO THE SCAN
TOOL
K1
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K1-K3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2891
K3-K4
Normal Operation
The satellite radio receiver communicates with the scan tool through the medium speed controller
area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -)
provide the network connection to the satellite radio receiver. The satellite radio receiver shares the
MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic
temperature control (EATC) module (if equipped), the audio unit, the digital versatile disc (DVD)
player (if equipped), the driver seat module (DSM) (if equipped), the power running board module
(if equipped), and the parking aid module (if equipped). Voltage for the satellite radio receiver is
provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground.
Possible Causes
- Fuse
- Circuit GD114 (BK/BU) open
- Circuit SBB41 (RD) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- Satellite radio receiver
Test L: The Digital Versatile Disc (DVD) Player Does Not Respond to the Scan Tool
PINPOINT TEST L: THE DIGITAL VERSATILE DISC (DVD) PLAYER DOES NOT RESPOND TO
THE SCAN TOOL
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L1-L2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2893
L3-L4
Normal Operation
The DVD player communicates with the scan tool through the medium speed controller area
network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -)
provide the network connection to the DVD player. The DVD player is only on vehicles equipped
with rear seat entertainment. The DVD player shares the MS-CAN network with the instrument
cluster, the smart junction box (SJB), the electronic automatic temperature control (EATC) module
(if equipped), the audio unit, the satellite radio receiver (if equipped), the driver seat module (DSM)
(if equipped), the digital versatile disc (DVD) player (if equipped), the power running board module
(if equipped), and the parking aid module (if equipped). Voltage for the DVD player is provided by
circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground.
Possible Causes
- Fuse
- Circuit GD114 (BK/BU) open
- Circuit SBB41 (RD) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- DVD player
Test M: The Driver Seat Module (DSM) Does Not Respond to the Scan Tool
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2894
PINPOINT TEST M: THE DRIVER SEAT MODULE (DSM) DOES NOT RESPOND TO THE SCAN
TOOL
M1
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M2-M3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2896
M4
Normal Operation
The DSM communicates with the scan tool through the medium speed controller area network
(MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the
network connection to the DSM. The DSM shares the MS-CAN network with the instrument cluster,
the smart junction box (SJB), the electronic automatic temperature control (EATC) module (if
equipped), the audio unit, the digital versatile disc (DVD) player (if equipped), the satellite radio
receiver (if equipped), the power running board module (if equipped) and the parking aid module (if
equipped). Voltage for the DSM is provided by circuit SBP01 (RD). Circuit GD143 (BK/OG)
provides ground.
Possible Causes
- Fuse
- Circuit GD143 (BK/OG) open
- Circuit SBP01 (RD) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- DSM
Test N: The Power Running Board Module Does Not Respond to the Scan Tool
PINPOINT TEST N: THE POWER RUNNING BOARD MODULE DOES NOT RESPOND TO THE
SCAN TOOL
N1
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N1-N2
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N3-N4
Normal Operation
The power running board module communicates with the scan tool through the medium speed
controller area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG)
(MS-CAN -) provide the network connection to the power running board module. The power
running board module shares the MS-CAN network with the instrument cluster, the smart junction
box (SJB), the electronic automatic temperature control (EATC) module (if equipped), the audio
unit, the digital versatile disc (DVD) player (if equipped), the driver seat module (DSM) (if
equipped), the satellite radio receiver (if equipped), and the parking aid module (if equipped).
Voltage for the power running board module is provided by circuit SBB19 (BU/RD). Circuit GD151
(BK/GN) provides ground.
Possible Causes
- Fuse
- Circuit GD151 (BK/GN) open
- Circuit SBB19 (BU/RD) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- Power running board module
Test O: The Parking Aid Module Does Not Respond to the Scan Tool
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2899
PINPOINT TEST O: THE PARKING AID MODULE DOES NOT RESPOND TO THE SCAN TOOL
O1-O3
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O3-O4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2901
O5-O6
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O7-O8
Normal Operation
The parking aid module communicates with the scan tool through the medium speed controller
area network (MS-CAN). Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -)
provide the network connection to the parking aid module. The parking aid module shares the
MS-CAN network with the instrument cluster, the smart junction box (SJB), the electronic automatic
temperature control (EATC) module (if equipped), the audio unit, the digital versatile disc (DVD)
player (if equipped), the satellite radio receiver (if equipped), and the power running board module
(if equipped). Voltage for the parking aid module is provided by circuit CBP18 (GY/OG). Circuit
GD145 (BK/BU) provides ground.
Possible Causes
- Fuse
- Circuit CBP18 (GY/OG) open
- Circuit GD145 (BK/BU) open
- Circuit VDB06 (GY/OG) open (MS-CAN +)
- Circuit VDB07 (VT/OG) open (MS-CAN -)
- Parking aid module
Test P: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2903
Not Responding PINPOINT TEST P: NO MEDIUM SPEED CONTROLLER AREA NETWORK
(MS-CAN) COMMUNICATION, ALL MODULES ARE NOT RESPONDING
P1-P2
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P2-P4
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P5-P7
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P7-P8
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P9-P12
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P12-P16
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P16-P20
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P20-P23
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2911
P23-P25
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2912
P25-P29
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2913
P29-P33
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2914
P33-P36
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2915
P37-P40
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2916
P41-P45
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2917
P46
Normal Operation
The MS-CAN network uses an unshielded twisted pair cable, circuits VDB06 (GY/OG) and VDB07
(VT/OG) provide the network connection to all modules on the network. The smart junction box
(SJB), the instrument cluster, the electronic automatic temperature control (EATC) module (if
equipped), the audio unit, the satellite radio receiver (if equipped), the digital versatile disc (DVD) (if
equipped), the power running board module (if equipped), the parking aid module (if equipped),
and the driver seat module all communicate with the scan tool using the MS-CAN network.
Possible Causes
- Circuit VDB06 (GY/OG) open, short to ground or voltage (MS-CAN +)
- Circuit VDB07 (VT/OG) open, short to ground or voltage (MS-CAN -)
- Circuit VDB06 (GY/OG) (MS-CAN +) and circuit VDB07 (VT/OG) (MS-CAN -) shorted together
- SJB
- Instrument cluster
- Audio unit
- EATC module (if equipped)
- DVD player (if equipped)
- Driver seat module (DSM) (if equipped)
- Satellite radio receiver (if equipped)
- Power running board module (if equipped)
- Parking aid module (if equipped)
Test Q: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not
Responding
PINPOINT TEST Q: NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN)
COMMUNICATION, ALL MODULES ARE NOT RESPONDING
Q1
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2918
Q1-Q2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2919
Q3-Q4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2920
Q5-Q6
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2921
Q7-Q8
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2922
Q8-Q9
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2923
Q10-Q11
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2924
Q12-Q16
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2925
Q16-Q18
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2926
Q18-Q20
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2927
Q20-Q23
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2928
Q23-Q26
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2929
Q26-Q28
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2930
Q28-Q30
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2931
Q31-Q34
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2932
Q35
Normal Operation
The HS-CAN uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH).
The powertrain control module (PCM), the transmission control module (TCM), the anti-lock brake
system (ABS) module, the restraints control module (RCM), the four wheel drive (4WD) control
module (if equipped), the occupant classification sensor module and the instrument cluster all
communicate with the scan tool using the HS-CAN.
Possible Causes
- Circuit VDB04 (WH/BU) open, short to ground or voltage (HS-CAN +)
- Circuit VDB05 (WH) open, short to ground or voltage (HS-CAN -)
- Circuit VDB04 (WH/BU) (HS-CAN +) and circuit VDB05 (WH) (HS-CAN -) shorted together
- PCM
- RCM
- ABS module
- Instrument cluster
- TCM (if equipped)
- 4WD control module (if equipped)
- Occupant classification sensor module
Test R: No Power to the Scan Tool
PINPOINT TEST R: NO POWER TO THE SCAN TOOL
R1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2933
R2-R3
Normal Operation
The scan tool is connected to the data link connector (DLC) to communicate with the high speed
controller area network (HS-CAN) and the medium speed controller area network (MS-CAN)
communications network. Voltage for the scan tool is provided by circuit SBP04 (GN/RD). Ground
is provided by circuits GD108 (BK/VT) and GD138 (BK/WH).
Possible Causes
- Fuse
- Circuit SBP04 (GN/RD) open
- Circuit GD108 (BK/VT) open
- Circuit GD138 (BK/WH) open
- Scan tool
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2934
Information Bus: Programming and Relearning
PROGRAMMABLE MODULE INSTALLATION
Special Tool(s)
Special Tool(s)
Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The
Original Module Is Available
NOTE: Following module installation, some modules require a separate learning procedure be
carried out. For instructions, refer to the specific module removal and installation procedures.
1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module
Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the
module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF
position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow
the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8.
The IDS downloads the data into the new module and displays Module Configuration Complete. 9.
Test module for correct operation.
Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The
Original Module Is Not Available
NOTE: Following module installation, some modules require a separate learning procedure be
carried out. For adaptive learning and calibration instructions, refer to the specific module removal
and installation procedures.
1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the
Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable
Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions,
turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen
instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not
available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data
from the technician service
publication website at this time and press the check mark.
9. Enter the module data and press the check mark.
10. The IDS downloads the data into the new module and displays Module Configuration
Complete. 11. Test module for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Testing and Inspection > Page 2935
Information Bus: Service and Repair
PROGRAMMABLE MODULE INSTALLATION
Special Tool(s)
Special Tool(s)
Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The
Original Module Is Available
NOTE: Following module installation, some modules require a separate learning procedure be
carried out. For instructions, refer to the specific module removal and installation procedures.
1. Connect the IDS and identify the vehicle as normal. 2. From the Toolbox icon, select Module
Programming and press the check mark. 3. Select Programmable Module Installation. 4. Select the
module that is being replaced. 5. Follow the on-screen instructions, turn the ignition key to the OFF
position, and press the check mark. 6. Install the new module and press the check mark. 7. Follow
the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 8.
The IDS downloads the data into the new module and displays Module Configuration Complete. 9.
Test module for correct operation.
Programmable Module Installation (PMI) Using The Integrated Diagnostic System (IDS) When The
Original Module Is Not Available
NOTE: Following module installation, some modules require a separate learning procedure be
carried out. For adaptive learning and calibration instructions, refer to the specific module removal
and installation procedures.
1. Install the new module. 2. Connect the IDS and identify the vehicle as normal. 3. From the
Toolbox icon, select Module Programming and press the check mark. 4. Select Programmable
Module Installation. 5. Select the module that was replaced. 6. Follow the on-screen instructions,
turn the ignition key to the OFF position, and press the check mark. 7. Follow the on-screen
instructions, turn the ignition key to the ON position, and press the check mark. 8. If the data is not
available, the IDS displays a screen stating to contact the As-Built Data Center. Retrieve the data
from the technician service
publication website at this time and press the check mark.
9. Enter the module data and press the check mark.
10. The IDS downloads the data into the new module and displays Module Configuration
Complete. 11. Test module for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Tools and Equipment > Module Communications Network
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Tools and Equipment > Module Communications Network > Page 2938
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams
C108
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Diagrams > Page 2942
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 2946
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 MIL notifies the driver that the powertrain control module (PCM) has detected an on board
diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD
diagnostic trouble code (DTC) sets.
- The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or the international standards organization (ISO) standard engine symbol.
- The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
- The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists.
- the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
- the PCM is operating in the hardware limited operation strategy (HLOS).
- The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster
concern is present.
- To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3
consecutive drive cycles must be completed without a concern.
- For all MIL concerns, go to Symptom Charts. See: Testing and Inspection/Symptom Related
Diagnostic Procedures
- If the MIL flashes at a steady rate, a severe misfire condition may exist.
- If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low.
- The MIL flashes after a period of time with the key in the RUN position (engine not running) if
DTC P1000 is set.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Description and Operation
Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Typical Manifold Absolute Pressure (MAP) Sensor
The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the
MAP sensor to measure how much exhaust gas is introduced into the intake manifold.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 2956
C104
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 2957
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical EOT Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance changes 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 sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control
gains and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM begins reducing power by disabling engine cylinders.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM
> Component Information > Locations > Page 2958
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil.
- Install the drain plug and tighten to 26 Nm (19 lb-ft).
3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature
sensor.
- To install, tighten to 15 Nm (11 lb-ft).
5. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Fill the engine with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2963
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2964
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2965
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22
C141
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2968
C142
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2969
C171
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2970
C172
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 2971
Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a 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
a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by
providing the ground when the correct conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2974
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S)
is being serviced, remove the bolts and position the heat shield aside.
- To install, tighten to 20 Nm (15 lb-ft).
3. Disconnect the HO2S electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2975
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft).
5. To install, reverse the removal procedure.
- Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2976
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2977
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Heated Oxygen Sensor (HO2S) > Page 2978
3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to
ease removal.
Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft).
4. To install, reverse the removal procedure.
- Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Diagrams
C121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 2984
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes 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 the transmission electronic pressure control (EPC) pressure during increased
engine load, for example, during parking maneuvers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation > Page 2988
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions
Pressure Release Valve Solenoid: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 2993
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 2994
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 2995
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 2996
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 2997
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 2998
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 2999
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3000
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3001
Pressure Release Valve Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3002
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3003
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3004
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3005
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3006
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3007
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3008
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Release Valve Solenoid
> Component Information > Diagrams > Diagram Information and Instructions > Page 3009
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) >
Page 3016
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration
information to a scan tool. This information must be downloaded into the new DSM after
installation.
1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors
and remove the DSM.
4. NOTE: Once the module is installed it is necessary to download the module configuration
information from the scan tool into the new module.
To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) >
Page 3017
Body Control Module: Service and Repair Smart Junction Box (Sjb)
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) >
Page 3018
Part 2
Removal
NOTE:
- The steps included in the SJB removal and installation procedure are critical to restoring the
vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered
in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure
monitoring system. The presence of these DTCs requires the installation procedures be followed in
order to clear the DTCs and enable normal SJB operations.
- Prior to the removal of the SJB, it is necessary to upload the module configuration information to
the diagnostic tool. This information must be downloaded to the new SJB after installation.
1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside.
3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for
the release lever to slide through the trim panel.
Remove the pushpin and the cowl side trim panel.
4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake
switch electrical connector. 6. Release the hood release cable pushpin from the parking brake
control bracket. 7. Release the harness clip from the parking brake cable housing.
8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the
instrument panel reinforcement.
Remove the 3 bolts and position the parking brake control assembly under the brake pedal.
9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the
instrument panel and may be broken if
any prying force is exerted in the lower area of the bezel.
Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the
instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside.
10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11.
Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the
instrument panel, remove the third SJB bolt.
13. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Service and Repair > Driver Seat Module (DSM) >
Page 3019
(connected) position when installing.
Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the
SJB.
Installation
NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program
the RKE transmitters to the new SJB.
1. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
(connected) position when installing.
Position the SJB into the 2 locating pins and connect the 5 electrical connectors.
2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel
opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5.
Connect the 2 electrical connectors and install the headlight switch bezel assembly into the
instrument panel. 6. Position the parking brake control assembly and install the 3 bolts.
- Tighten to 20 Nm (15 lb-ft).
7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable
pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical
connector.
10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release
lever assembly and install the bolt.
12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the
release lever to slide through the trim panel.
Position the cowl side trim panel and install the pushpin.
13. Position the LH door opening weather seal. 14. Install the driver door scuff plate.
15. NOTE: When successful, this step provides the calibration necessary for SJB operation and
clears DTC B2477. The clearing of the DTC
indicates the calibration data has been successfully downloaded to the SJB.
Download the SJB configuration information from the diagnostic tool to the SJB.
16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing
of these DTCs indicates the SJB has recognized
the tire pressure sensors during the training procedure.
Train the tire pressure sensors.
17. Clear the DTCs.
18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing
mode, and to be sure there are no other concerns with
the newly programmed SJB.
Carry out the SJB on-demand self-test.
19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters
do not need to be reprogrammed to the vehicle.
However, if the module configuration upload/download is unsuccessful and as-built data must be
used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed
to the vehicle.
Program the RKE transmitters to the new SJB (if necessary).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation
Electronic Throttle Control Module: Description and Operation
TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The torque based ETC is a hardware and software strategy that delivers an engine output torque
(via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the
powertrain control module (PCM), and an accelerator pedal assembly to control the throttle
opening and engine torque. The ETC system replaces the standard cable operated accelerator
pedal, idle air control (IAC) valve, 3-wire throttle position (TP) sensor, and mechanical throttle body.
Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable camshaft
timing (VCT) (deliver same torque during transitions).
Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of ETC are: eliminate cruise control actuators
- eliminate idle air control (IAC) valve
- better airflow range
- packaging (no cable)
- more responsive powertrain at altitude and improved shift quality
It should be noted that the ETC system illuminates a powertrain malfunction indicator (wrench) on
the instrument cluster when a concern is present. Concerns are accompanied by diagnostic trouble
codes (DTCs) and may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The ETB has the following characteristics: 1. The throttle actuator control (TAC) motor is a DC
motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle
plate shaft is 17:1.
2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore
parallel to the plate shaft. The motor housing is
integrated into the main housing. The in-series design has a separate motor housing.
3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger
assembly that results in a default angle when no
power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger
than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h
(30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle.
4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (~0.75
degree). This hard stop setting is not adjustable
and is set to result in less airflow than the minimum engine airflow required at idle.
5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle
plate or to use plate sealant. The hole is not
required in the ETB because the required idle airflow is provided by the plate angle in the throttle
body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC
valve.
6. The TP sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position
signals are required for increased monitoring
reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and
the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal
operation the negative slope TP signal (TP1) is used by the control strategy as the indication of
throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage
- Signal return (ground)
- TP1 voltage with negative voltage slope (5-0 volts)
- TP2 voltage with positive voltage slope (0-5 volts)
Accelerator Pedal Position (APP) Sensors
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3023
Electronic Throttle Body (ETB) And Accelerator Pedal Assembly
The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1.
There are 3 pedal position signals required for system monitoring. APP1 has a negative slope
(increasing angle, decreasing voltage) and APP2 and
APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation
APP1 is used as the indication of pedal position by the strategy.
2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and
pins) between the PCM and the APP sensor
assembly. 2 reference voltage circuits (5 volts)
- 2 signal return (ground) circuits
- APP1 voltage with negative voltage slope (5-0 volts)
- APP2 voltage with positive voltage slope (0-5 volts)
- APP3 voltage with positive voltage slope (0-5 volts)
3. The pedal position signal is convened to pedal travel degrees (rotary angle) by the PCM. The
software then converts these degrees to counts,
which is the input to the torque based strategy.
4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a
concern. The PCM determines if a signal is
incorrect by calculating where it should be, inferred from the other signals. A value is substituted for
an incorrect signal if 2 of the 3 signals are incorrect.
Electronic Throttle Control (ETC) System Strategy
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3024
ETC System
The torque based ETC strategy was developed to improve fuel economy and to accommodate
variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver
pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer)
processor. The primary monitoring function is carried out by the independent plausibility check
(IPC) software, which resides on the main processor. It is responsible for determining the
driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the
generated torque exceeds driver demand by a specified amount, the IPC takes appropriate
corrective action.
ETC System Failure Mode And Effects Management (Part 1)
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and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
3025
ETC System Failure Mode And Effects Management (Part 2)
Since the IPC and the main controller share the same processor, they are subject to a number of
potential common failure modes. The E-Quizzer processor was added to redundantly monitor
selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC
and the main processor. If it determines that the IPC function is impaired in any way, it takes
appropriate failure mode and effects management (FMEM) actions.
Electronic Throttle Monitor Operation:
Electronic Throttle Monitor Operation (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
3026
Electronic Throttle Monitor Operation (Part 2)
Accelerator and Throttle Position (TP) Sensor Inputs
Accelerator Pedal Position (APP) Sensor Check:
Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check:
Throttle Position (TP) Sensor Check
Throttle Plate Position Controller (TPPC) Outputs
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
3027
Throttle Plate Controller Check Operation
The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a
separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a
312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 4% - Out of range, limp home default position.
- Greater than or equal to 4% but less than 6% - Commanded default position, closed.
- Greater than or equal to 6% but less than 7% - Commanded default position. Used for key ON,
engine OFF.
- Greater than or equal to 7% but less than 8% - Enable ice breaker mode. Used to clear potential
ice buildup in the throttle body.
- Greater than or equal to 8% but less than 10% - Closed against hard-stop. Used to learn zero
throttle angle position (hard stop) after key-up.
- Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0
degrees (hard stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty
cycle equals 82 degrees throttle angle.
- Greater than 92% but less than or equal to 96% - Wide open throttle, 82 to 86 degrees throttle
angle.
- Greater than 96% but less than or equal to 100% - Out of range, limp home default position.
The desired angle is relative to the hard-stop angle. The hard stop angle is learned during each
key-up process before the main CPU requests the throttle plate be closed against the hard stop.
The output of the TPPC is a voltage request to the H driver (also in PCM). The H driver is capable
of positive or negative voltage to the electronic throttle body motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Locations
Engine Control Module: Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Locations > Page 3031
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Engine Control Module: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3034
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3035
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3036
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3037
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3038
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3039
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3040
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3041
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3042
Engine Control Module: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3043
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3044
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3045
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3046
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3047
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3048
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3049
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3050
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3051
Engine Control Module: Connector Views
C175B (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3052
C175B (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3053
C175E (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3054
C175E (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3055
C175T (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3056
C175T (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module
(PCM)
Engine Control Module: Service and Repair Powertrain Control Module (PCM)
POWERTRAIN CONTROL MODULE (PCM)
Removal
All vehicles
1. NOTE: Powertrain control module (PCM) installation DOES NOT require new keys.
Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation procedure.
Vehicles equipped with a 4.6L (3V) engine 2. Remove the air cleaner.
All vehicles
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module
(PCM) > Page 3059
3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nuts and position
the A/C tube brackets and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove
the bolts and the PCM.
Installation
All vehicles
1. Install the PCM and bolts.
- Tighten to 10 Nm (89 lb-in).
2. Connect the PCM electrical connectors.
3. Position the wiring harness and the A/C tube brackets and install the nuts. Connect the RH front
wheel speed sensor electrical connector.
- Tighten to 7 Nm (62 lb-in).
Vehicles equipped with a 4.6L (3V) engine 4. Install the air cleaner.
All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps
of the Programmable Module Installation procedure. 6. Reprogram the passive anti-theft system
(PATS). Carry out the Parameter Reset procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Service and Repair > Powertrain Control Module
(PCM) > Page 3060
Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only
Memory (EEPROM)
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit (IC) internal to the powertrain control module
(PCM). The EEPROM contains the vehicle strategy including calibration information specific to the
vehicle, and is capable of being programmed or flashed repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate DTCs P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block is displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan
tool manufacturer's instruction manual for details.
Programming the VID Block for a Replacement PCM
A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the
VID block is blank and needs programming. There are 2 procedures available. The first is an
automatic data transfer from the old PCM to the new PCM, and the second is manual data entry
into the new PCM.
Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by
using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored
data can then be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old module is damaged or incapable of communicating. Remove
and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter
programming, referring to the scan tool manufacturer's instruction manual. Make certain that all
parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile
equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF
may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center
for the information needed to manually update the VID block with the scan tool. Contact the center
only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury
technicians, contact your National Hotline or the Professional Technician Society (PTS) website for
As-Built data listed under the Service Publications Index. Non-Ford technicians use the
Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) homepage, use the search
function to find the Module Programming or As-Built Data.
For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the
PTS website for quick Programmable Module data information by vehicle.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate the vehicle hardware. Refer to Module Reprogramming on the scan tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production, or the need to reset the VID block
because it has reached its limit. Refer to Module Reprogramming on the scan tool.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-12 (behind Dash Panel)
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C2040
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3070
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
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C128
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3075
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3076
Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3077
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position
Sensor 1
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position
Sensor 1 > Page 3082
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor
C180
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor > Page 3085
C1366
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position
Sensor > Page 3086
C1367
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3087
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3088
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
C1064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3098
Crankshaft Position Sensor: Diagrams
C101
C1120
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3099
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3100
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3101
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3105
C107
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3106
Engine Temperature Sensor: Description and Operation
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Typical CHT Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases., and the resistance
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.
The CHT sensor is installed in the 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 initiates a
fail-safe cooling strategy based on information from the CHT sensor. A cooling system concern
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.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3107
Engine Temperature Sensor: Service and Repair
CYLINDER HEAD TEMPERATURE (CHT) SENSOR
Removal and Installation
1. Disconnect the battery ground cable. 2. Remove the intake manifold. 3. Disconnect the cylinder
head temperature (CHT) sensor electrical connector. 4. Remove and discard the CHT sensor.
- To install, tighten to 26 Nm 19 lb-ft).
5. To install, reverse the removal procedure.
- Do not reuse the CHT sensor. Install a new sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3111
Fuel Level Sensor: Diagrams
C434A
C434B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3112
Fuel Level Sensor: Description and Operation
FUEL LEVEL INPUT (FLI)
The FLI is a communications network message. Most vehicle applications use a potentiometer type
FLI sensor connected to a float in the FP module to determine fuel level.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3113
Fuel Level Sensor: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3114
Explorer Sport Trac (Part 2)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3115
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3116
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3117
All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3118
4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3119
4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation
Fuel Tank Pressure Sensor: Description and Operation
FUEL TANK PRESSURE (FTP) SENSOR
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Description and Operation >
Page 3123
Fuel Tank Pressure Sensor: Service and Repair
FUEL TANK PRESSURE SENSOR
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents a danger or 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 cause 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.
1. Remove the evaporative emission (EVAP) canister.
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Page 3124
2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the fuel tank pressure sensor
electrical connector. 4. Disconnect the 3 fuel tank pressure sensor and tube assembly quick
connect couplings from the fuel pump module and the vapor vent valves. 5. Remove the fuel tank
pressure sensor and tube assembly. 6. To install, reverse the removal procedure. 7. Leak test the
evaporative emission system. See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection/Evaporative
Emission System Leak Test
8. Carry out the evaporative emission repair verification drive cycle. See: Emission Control
Systems/Evaporative Emissions System/Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3128
C128
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3129
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE (IAT) SENSOR
Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors
Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange-type
MAF Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance 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 air flow.
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The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 design types of IAT sensors used, a stand-alone/non-integrated type and a
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described. One is located before the supercharger at the air cleaner for standard OBD/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 spark and to help determine charge air cooler (CAC) efficiency.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams
C108
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 3134
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and
Operation
Manifold Pressure/Vacuum Sensor: Description and Operation
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Typical Manifold Absolute Pressure (MAP) Sensor
The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the
MAP sensor to measure how much exhaust gas is introduced into the intake manifold.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3141
C104
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3142
Oil Temperature Sensor For ECM: Description and Operation
ENGINE OIL TEMPERATURE (EOT) SENSOR
Typical EOT Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance
increases as the temperature decreases. The varying resistance changes 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 sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM can use the EOT sensor input to determine the
following:
- On variable camshaft timing (VCT) applications the EOT input is used to adjust the VCT control
gains and logic for camshaft timing.
- The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil
degradation.
- The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine
damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft
engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time,
the PCM begins reducing power by disabling engine cylinders.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Locations > Page 3143
Oil Temperature Sensor For ECM: Service and Repair
OIL TEMPERATURE SENSOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil.
- Install the drain plug and tighten to 26 Nm (19 lb-ft).
3. Disconnect the oil temperature sensor electrical connector. 4. Remove the oil temperature
sensor.
- To install, tighten to 15 Nm (11 lb-ft).
5. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Fill the engine with clean engine oil.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3148
View 151-8 (Engine, Rear - 4.6L)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3149
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S)
#11 > Page 3150
View 151-8 (Engine, Rear - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22
C141
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#22 > Page 3153
C142
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#22 > Page 3154
C171
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#22 > Page 3155
C172
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Oxygen Sensor: Description and Operation
HEATED OXYGEN SENSOR (HO2S)
Heated Oxygen Sensor (HO2S)
The HO2S 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 voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a 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
a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine can enter closed
loop operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by
providing the ground when the correct conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S)
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
HEATED OXYGEN SENSOR (HO2S)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 3159
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH heated oxygen sensor (HO2S)
is being serviced, remove the bolts and position the heat shield aside.
- To install, tighten to 20 Nm (15 lb-ft).
3. Disconnect the HO2S electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 3160
4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal.
Using the special tool, remove the HO2S. To install, tighten to 41 Nm (30 lb-ft).
5. To install, reverse the removal procedure.
- Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 3161
Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
CATALYST MONITOR SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 3162
Exploded View
Special Tool(s)
Special Tool(s)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the catalyst monitor sensor
electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) > Page 3163
3. NOTE: If necessary, lubricate the catalyst monitor sensor with penetrating and lock lubricant to
ease removal.
Using the special tool, remove the catalyst monitor sensor. To install, tighten to 41 Nm (30 lb-ft).
4. To install, reverse the removal procedure.
- Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Diagrams
C121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation
> Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation
> Power Steering Pressure (PSP) Switch > Page 3169
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes 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 the transmission electronic pressure control (EPC) pressure during increased
engine load, for example, during parking maneuvers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and
Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and
Operation > Page 3173
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
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C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Electronic Throttle Body (ETB) Position Sensor > Page 3180
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page
3181
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
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Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3187
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3188
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3189
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Diagram Information and Instructions > Page 3190
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Diagram Information and Instructions > Page 3191
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3192
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3193
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3194
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3195
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3196
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3197
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3198
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3199
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3200
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3201
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
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Diagram Information and Instructions > Page 3202
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Diagram Information and Instructions > Page 3203
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Diagram Information and Instructions > Page 3204
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the 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 that is
generated.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor > Page 3209
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3213
C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3216
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 3217
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 3218
Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3223
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3224
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3225
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3226
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3227
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3228
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3229
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3230
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3231
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3232
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3233
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3234
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3235
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3236
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3237
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3238
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3239
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3240
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1
C1451
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Variable Camshaft Timing (VCT) Valve 1 > Page 3245
C1452
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Page 3246
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAMSHAFT TIMING (VCT) SYSTEM
Overview
The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of
engine operating conditions. There are 4 types of VCT systems. Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake phase shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default
mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM)
determines the phase angle based on air flow, engine oil temperature and engine coolant
temperature. At part and wide open throttle the PCM determines the phase angle based on engine
RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine
power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque.
In addition, some VCT system applications can eliminate the need for an external exhaust gas
recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the
overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS
and DEPS systems are used.
Variable Camshaft Timing (VCT) System
VCT System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth
equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8
engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The
extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A
crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10
degree increments. 1. The PCM receives input signals from the intake air temperature (IAT)
sensor, engine coolant temperature (ECT) sensor, engine oil temperature
(EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to
determine the operating conditions of the engine. At idle and low engine speeds with closed
throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part
and wide open throttle, the camshaft position is determined by engine RPM, load and throttle
position. The VCT system does not operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It continually updates the VCT
solenoid duty cycle until the desired position is achieved. A difference between the desired and
actual camshaft position represents a position error in the PCM VCT control loop. The PCM
disables the VCT and places the camshaft in a default position if a concern is detected. A related
DTC is also set when the concern is detected.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Diagrams > Page 3247
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the camshaft timing.
One half of the VCT actuator is coupled to the camshaft and the other half is connected to the
timing chain. Oil chambers between the 2 halves couple the camshaft to the timing chain. When
the flow of oil is shifted from one side of the chamber to the other, the differential change in oil
pressure forces the camshaft to rotate in either an advance or retard position depending on the oil
flow.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Service and Repair
Variable Valve Timing Solenoid: Service and Repair
VARIABLE CAMSHAFT TIMING (VCT) OIL CONTROL SOLENOID
Removal and Installation
1. Remove the valve cover. 2. Remove the bolt and the VCT oil control solenoid.
- To install, tighten to 5 Nm (44 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
OUTPUT SHAFT SPEED (OSS) SENSOR
The OSS sensor provides the 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 that is
generated.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3255
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
VEHICLE SPEED SENSOR (VSS)
Typical Vehicle Speed Sensor (VSS)
The VSS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Description and Operation
Air Diverter Solenoid: Description and Operation
SECONDARY AIR INJECTION (AIR) BYPASS SOLENOID
Secondary AIR Bypass Solenoid
The secondary AIR bypass solenoid is used by the PCM to control vacuum to the secondary air
injection diverter (AIR diverter) valve. The secondary AIR bypass solenoid is a normally closed
solenoid. The secondary AIR bypass solenoid also has a filtered vent feature to permit vacuum
release.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation
Air Diverter Valve: Description and Operation
SECONDARY AIR DIVERTER VALVE
Secondary AIR Diverter Valve
The secondary AIR diverter valve is used with the secondary AIR pump to provide on/off control of
air to the exhaust manifold and catalytic converter. When the secondary AIR pump is on and
vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the
secondary 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 system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Description and Operation
Air Injection Pump: Description and Operation
SECONDARY AIR PUMP
Secondary Air Pump
The secondary AIR pump provides pressurized air to the secondary AIR system. The secondary
AIR pump functions independently of RPM and is controlled by the PCM. The secondary 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 secondary AIR pump draws dry filtered air from the intake
air system downstream of the MAF/IAT sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation
Catalytic Converter: Description and Operation
CATALYST AND EXHAUST SYSTEMS
Overview
V-Engines
In-Line Engines
The catalytic converter and exhaust Systems work together to control the release of harmful engine
exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N),
carbon dioxide (CO2) and water vapor (H2O) However, it also contains carbon monoxide (CO),
oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air
pollutants of CO, NOx, and HCs, and their emission into the atmosphere must be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated
oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the PCM.
For information on the OBD catalyst monitor, refer to the description for the Catalyst Efficiency
Monitor. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive
Cycles and Readiness Codes/Monitors/Catalyst Efficiency Monitor
The number of HO2Ss used in the exhaust stream and the location of these sensors depend on the
vehicle emission certification level (LEV, LEV-II, ULEV, PZEV). On most vehicles only 2 HO2Ss are
used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst are used for
primary fuel control while the ones after the catalyst (HO2S12/HO2S22) are used to monitor
catalyst efficiency. However, some partial zero emission vehicles (PZEV) use 3 HO2Ss for each
engine bank. The stream 1 sensors (HO2S11/HO2S21) located before the catalyst are used for
primary fuel control, the stream 2 sensors (HO2S12/HO2S22) are used to monitor the light-off
catalyst, and the stream 3 sensors (HO2S13/HO2S23) located after the catalyst are used for long
term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). Current PZEV
vehicles use only a 4-cylinder engine, so only the bank 1 HO2Ss are used.
Catalytic Converter
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3270
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst also enables 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 246°C to 302°C
(475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the
exhaust manifold as possible. Because the light off catalyst is located close to the exhaust manifold
it lights off faster and reduces emissions more quickly than the catalyst located under the body.
Once the catalyst lights off, the catalyst quickly reaches the maximum conversion efficiency for that
catalyst.
Three-Way Catalyst (TWC) Conversion Efficiency
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. Deviations outside of this window greatly
decrease the conversion efficiency. For example a rich mixture decreases the HC and CO
conversion efficiency while a lean mixture decreases the NOx conversion efficiency.
Exhaust System
Typical Bank 1 Catalyst 2 HO2S Configuration
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3271
Typical Bank 1 Catalyst 3 HO2S Configuration
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. A HO2S is mounted on the front exhaust pipe
before the catalyst. The catalytic converter reduces the concentration of CO, unburned HCs, and
NOx in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed
from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into
the muffler. Finally, the exhaust emissions are directed to the atmosphere through an exhaust
tailpipe.
On some PZEV, there is a total of 3 HO2S in the exhaust stream. One near the exhaust manifold
(stream 1), one in the middle of the light-off catalyst (stream 2), and the third (stream 3) is mounted
after the light-off catalyst.
Underbody Catalyst
The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line
with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming
a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific
vehicle, refer to Catalytic Converter, Exhaust System.
Three-Way Catalytic (TWC) Converter
The 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 3-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.
Heated Oxygen Sensor (HO2S)
The HO2Ss provide the powertrain control module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas.
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 also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams
C1195
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 3276
Canister Purge Control Valve: Description and Operation
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE
Typical EVAP Canister Purge Valve
NOTE: The EVAP canister purge valve may also be referred to as a vapor management valve
(VMV).
The EVAP canister purge valve is part of the enhanced EVAP system that is controlled by the
PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold
during various engine operating modes. The EVAP canister purge valve is a normally closed valve.
The EVAP canister purge valve controls the flow of vapors by way of a solenoid, eliminating the
need for an electronic vacuum regulator and vacuum diaphragm. The PCM outputs a signal
between 0 mA and 1,000 mA to control the EVAP canister purge valve.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams > Page 3277
Canister Purge Control Valve: Service and Repair
EVAPORATIVE EMISSION CANISTER PURGE VALVE
Removal and Installation
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 vapors 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.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the evaporative emission (EVAP) canister purge valve electrical connector. 4.
Disconnect the 2 vapor tube quick connect couplings from the EVAP canister purge valve. 5.
Detach the EVAP canister purge valve from the bracket and remove. 6. To install, reverse the
removal procedure. 7. Leak test the evaporative emission system. See: Testing and
Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair
verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive
Cycle
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service and Repair
Evaporative Canister Filter: Service and Repair
DUST SEPARATOR
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
NOTE: Use only water-based lubricants on the vapor hoses.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the fuel vapor hose from the dust separator. 4. Disconnect the fuel filler pipe vapor
hose from the dust separator. 5. Remove the bolt and the dust separator.
- To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure.
- Lubricate the vapor hoses with a water-based lubricant to ease installation.
7. Leak test the evaporative emission system. See: Testing and Inspection/Evaporative Emission
System Leak Test 8. Carry out the evaporative emission repair drive cycle. See: Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Service and Repair
Evaporative Emission Control Canister: Service and Repair
EVAPORATIVE EMISSION CANISTER
Removal and Installation
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.
NOTE: Use only water-based lubricants on the vapor hoses.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the fuel tank. 4. Detach the evaporative emission (EVAP) canister from the fuel tank to
gain access to the quick connect coupling. 5. Disconnect the fuel tank pressure sensor and tube
assembly quick connect coupling from the EVAP canister. 6. Disconnect the vapor hose from the
EVAP canister. 7. Remove the EVAP canister. 8. To install, reverse the removal procedure.
- Lubricate the vapor hoses with a water-based lubricant to ease installation.
9. Leak test the evaporative emission system. See: Testing and Inspection/Evaporative Emission
System Leak Test
10. Carry out the evaporative emission repair verification drive cycle. See: Testing and
Inspection/Evaporative Emission Repair Verification Drive
Cycle
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Diagrams
C450
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Diagrams > Page 3287
Leak Detection Valve: Description and Operation
CANISTER VENT (CV) SOLENOID
Typical Canister Vent (CV) Solenoid
During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP
canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the
target vacuum in the fuel tank during the EVAP leak check monitor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Service and Repair
Liquid Vapor Separator: Service and Repair
FUEL VAPOR VENT VALVE
Removal and Installation
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery
ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly
causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these
instructions can result in personal injury.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any
fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
NOTE: Use only water-based lubricants on the vapor hoses.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Disconnect the fuel vapor vent valve electrical connector. 4. Disconnect the fuel vapor hoses from
the fuel vapor vent valve and remove the fuel vapor vent valve. 5. To install, reverse the removal
procedure.
- Lubricate the vapor hoses with a water-based lubricant to ease installation.
6. Leak test the evaporative emission system. See: Testing and Inspection/Evaporative Emission
System Leak Test 7. Carry out the evaporative emission repair drive cycle. See: Testing and
Inspection/Evaporative Emission Repair Verification Drive Cycle
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Module > Component Information > Diagrams
C1450
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation
EGR Electronic Vacuum Regulator Solenoid: Description and Operation
EXHAUST GAS RECIRCULATION (EGR) VACUUM REGULATOR SOLENOID
EGR Vacuum Regulator Solenoid
Vacuum Output (IN-HG)
EGR Vacuum Regulator Solenoid Data
The EGR vacuum regulator solenoid is an electromagnetic device 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Description and Operation
EGR Tube: Description and Operation
EXHAUST GAS RECIRCULATION (EGR) ORIFICE TUBE ASSEMBLY
EGR Orifice Tube Assembly
The orifice tube assembly 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 2 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve
EGR Valve: Description and Operation Electric Exhaust Gas Recirculation (EEGR) Valve
ELECTRIC EXHAUST GAS RECIRCULATION (EEGR) VALVE
EEGR Motor/Valve Assembly
Depending on the application, the EEGR valve is a water cooled or an air cooled motor/valve
assembly. The motor is commanded to move in 52 discrete steps as it acts directly on the EEGR
valve. The position of the valve determines the rate of EGR. The built-in spring works to close the
valve (against the motor opening force).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 3305
EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) System Module (ESM)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM MODULE (ESM)
ESM
The ESM is an integrated differential pressure feedback EGR system that functions in the same
manner as a conventional differential pressure feedback EGR system. The various system
components have been integrated into a single component called the ESM. The flange of the valve
portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the metering
orifice. This arrangement increases system reliability, response time, and system precision. By
relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream
pressure signal measures manifold absolute pressure (MAP). This MAP signal is used for EGR
correction and inferred barometric pressure (BARO) at key on. The system provides the powertrain
control module (PCM) with a differential pressure feedback EGR signal, identical to a traditional
differential pressure feedback EGR system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 3306
EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve
EXHAUST GAS RECIRCULATION (EGR) VALVE
Typical EGR Valve
EGR Flowrate
The EGR valve in the differential pressure feedback EGR system is a conventional,
vacuum-actuated. The valve increases or decreases the flow of EGR. 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 repair specifications on flow rate is
impractical. The on board diagnostic (OBD) system monitors the EGR valve function and triggers a
diagnostic trouble code (DTC) if the test criteria is not met. The EGR valve flow rate is not
measured directly as part of the diagnostic procedures.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Description and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 3310
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Diagrams
C190
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > EGR Control Module > Component Information > Diagrams
C1450
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
The differential pressure feedback EGR sensor 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 EGR sensor receives this signal through 2 hoses referred to as
the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI SIGNAL). The HI
and REF hose connections are marked on the differential pressure feedback EGR sensor housing
for identification (note that the HI signal uses a larger diameter hose). The differential pressure
feedback EGR sensor outputs a voltage proportional to the pressure drop across the metering
orifice and supplies it to the PCM as EGR flow rate feedback.
DIFFERENTIAL PRESSURE FEEDBACK EXHAUST GAS RECIRCULATION (EGR) SENSOR TUBE MOUNTED
Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation >
Page 3323
The tube mounted differential pressure feedback EGR sensor is identical in operation as the large
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Fuel Pressure
Key on, engine off.................................................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
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.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow
it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to
make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key
and wait 3 seconds to pressurize the fuel system.
Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame
scuff plate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Hot Idle Speed .....................................................................................................................................
............................................................ 630-850 RPM
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 3337
Accelerator Pedal: Description and Operation
Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver
can adjust the brake and accelerator pedals for a more comfortable driving position. For removal
and installation of the adjustable pedals, refer to Brake Pedal and Bracket.
Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational
with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward
using the adjustable pedal switch.
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal - Fixed
Accelerator Pedal: Service and Repair Accelerator Pedal - Fixed
ACCELERATOR PEDAL - FIXED
Removal and Installation
1. Disconnect the accelerator pedal electrical connector. 2. Remove the nuts and the accelerator
pedal assembly.
- To install, tighten to 7 Nm (62 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Accelerator Pedal - Fixed > Page 3340
Accelerator Pedal: Service and Repair Accelerator Pedal - Adjustable
ACCELERATOR PEDAL - ADJUSTABLE
Removal and Installation
1. The adjustable accelerator pedal and adjustable brake pedal must be serviced as a unit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 3344
C2040
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >
Component Information > Locations > Page 3345
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
AIR CLEANER ELEMENT
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 3350
Exploded View
Removal and Installation
NOTE: Do not disconnect the mass air flow (MAF) sensor electrical connector.
Vehicles equipped with a 4.0L (SOHC) engine
1. Detach the wiring harness retainer from the air cleaner outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 3351
2. Detach the wiring harness retainer from the coolant expansion tank.
All vehicles
3. Loosen the clamp and disconnect the air cleaner outlet pipe from the air cleaner. 4. Unclip and
remove the air cleaner cover. 5. Remove the air cleaner element.
6. NOTE: Clean the inside of the air cleaner tray.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3355
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3356
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3357
Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Locations > Page 3358
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator >
Component Information > Description and Operation
Fuel Filler Cap Warning Indicator: Description and Operation
CHECK FUEL CAP INDICATOR
The check fuel cap indicator is a communications network message sent by the PCM. The PCM
sends the message to illuminate the lamp when the strategy determines that there is a failure in the
vapor management system due to the fuel filler cap not being sealed correctly. This would be
detected by the inability to pull vacuum in the fuel tank, after a fueling event.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair
Fuel Pressure Release: Service and Repair
FUEL SYSTEM PRESSURE RELEASE
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.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Start the engine and allow
it to idle until it stalls. 5. After the engine stalls, crank the engine for approximately 5 seconds to
make sure the fuel rail pressure has been released. 6. Turn the ignition switch to the OFF position.
7. When the fuel system service is complete, reconnect the IFS switch electrical connector.
8. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key
and wait 3 seconds to pressurize the fuel system.
Check for leaks before starting the engine.
9. Start the vehicle and check the fuel system for leaks.
10. Install the front passenger side interior kick panel. 11. Install the front passenger door frame
scuff plate.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Resistance ...........................................................................................................................................
............................................................. 11 - 18 Ohms
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1
C181
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3372
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Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3373
C183
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3374
C184
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3375
Fuel Injector: Diagrams
C181
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Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3376
C183
C184
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3377
C185
C186
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1 > Page 3378
C187
C188
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3379
Fuel Injector: Description and Operation
FUEL INJECTORS
Typical Fuel Injector
CAUTION: Do not apply battery positive voltage (B+) directly to the fuel injector electrical connector
terminals. The solenoids may be damaged internally in a matter of seconds.
The fuel injector is a solenoid-operated valve that meters fuel flow to the engine. The fuel injector is
opened and closed a constant number of times per crankshaft revolution. The amount of fuel is
controlled by the length of time the fuel injector is held open.
The fuel injector is normally closed, and is operated by a 12-volt source from either the electronic
engine control (EEC) power relay or fuel pump relay. The ground signal is controlled by the PCM.
The injector is the deposit resistant injector (DRI) type and does not have to be cleaned. However,
it can be flow checked and, if found outside of specification, a new fuel injector should be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings
Fuel Line Coupler: Service and Repair Spring Lock Couplings
SPRING LOCK COUPLINGS
Special Tool(s)
Special Tool(s)
Disconnect - Type I
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 can 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
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any
type when working on or near any fuel-related components. Highly flammable mixtures are always
present and can be ignited. Failure to follow these instructions may result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always
observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
CAUTION:
- If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be
installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material.
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
- Do not use any tools. Use of tools may cause a deformity in the coupling components which can
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3384
3. Disconnect the safety clip from the fuel tube.
4. Install the special tool and press it into the spring lock coupling.
5. Separate the spring lock coupling.
Connect - Type I
1. Inspect and clean both spring lock coupling ends.
2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that
the fuel tube is fully seated, pull on the
tube.
NOTE: Lubricate the spring lock coupling with clean engine oil.
Align the fuel tube spring lock coupling and push together until a click is heard.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3385
3. Pull on the spring lock coupling to make sure it is fully seated. Install the safety clip.
Disconnect - Type II
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 can 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
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any
type when working on or near any fuel-related components. Highly flammable mixtures are always
present and can be ignited. Failure to follow these instructions may result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always
observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
CAUTION:
- If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be
installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material.
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube.
- Do not use any tools. Use of tools may cause a deformity in the coupling components which can
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable.
3. Remove the fuel tube clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3386
4. Install the special tool.
5. Close and push the special tool into the open side of the cage.
6. Separate the spring lock coupling.
Connect - Type II
1. NOTE: Apply clean engine oil to O-ring seals.
Inspect and clean both spring lock coupling ends. Install new O-ring seals and garter springs if
necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3387
2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that
the fuel tube is fully seated, pull on the
tube.
Fit the male end into the female end and push until the garter spring snaps over the flared end of
the female end.
3. Make sure the spring lock coupling is engaged by pulling on the lines and install the safety clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3388
Fuel Line Coupler: Service and Repair Quick Connect Coupling
QUICK CONNECT COUPLING
Disconnect - Type I
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.
- 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, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any
type when working on or near any fuel-related components. Highly flammable mixtures are always
present and can be ignited. Failure to follow these instructions may result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always
observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
CAUTION:
- If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be
installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material.
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube. Apply clean
engine oil to the end of the tube before inserting the tube into the connector.
- Do not use any tools. Use of tools may cause a deformity in the coupling components which can
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground
cable.
3. Unclip the locking tab.
4. Depress the tabs and press the clip downward.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3389
5. Separate the quick connect coupling.
Connect - Type I
1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that
the fuel tube is fully seated, pull on the
tube.
NOTE: Lubricate the quick connect coupling with clean engine oil.
Connect the quick connect coupling.
3. Push the clip up into the quick connect coupling. Pull on the tube to make sure it is seated
correctly.
4. Clip the locking tab in place.
Disconnect - Type II
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3390
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents 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.
- 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, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any
type when working on or near any fuel-related components. Highly flammable mixtures are always
present and can be ignited. Failure to follow these instructions may result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always
observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
CAUTION:
- If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be
installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material.
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube. Apply clean
engine oil to the end of the tube before inserting the tube into the connector.
- Do not use any tools. Use of tools may cause a deformity in the coupling components which can
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground
cable.
3. Disconnect the fuel tube quick connect coupling.
- Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect.
Connect - Type II
1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3391
2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that
the fuel tube is fully seated, pull on the
tube.
NOTE: Apply clean engine oil to O-ring seals.
Install the quick connect coupling onto the tube until it is fully seated.
Disconnect - Type III
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents 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.
- 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, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any
type when working on or near any fuel-related components. Highly flammable mixtures are always
present and can be ignited. Failure to follow these instructions may result in personal injury.
CAUTION:
- If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be
installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material.
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube. Apply clean
engine oil to the end of the tube before inserting the tube into the connector.
- Do not use any tools. Use of tools may cause a deformity in the coupling components which can
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. Disconnect the battery ground cable.
2. Release the locking tab on the quick connect coupling.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3392
3. Separate the quick connect coupling from the fitting.
Connect - Type III
1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that
the fuel tube is fully seated, pull on the
tube.
NOTE: Apply clean engine oil to O-ring seals.
Release the locking tab and install the quick connect coupling onto the fitting.
3. Position the locking tab into the latched position.
Disconnect - Type IV
WARNING:
- The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not
present in large quantities, it still presents 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.
- 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, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any
type when working on or near any
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3393
fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure
to follow these instructions may result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always
observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
CAUTION:
- If the liquid or vapor tube is damaged (torn, holes or delaminated), a new tube assembly must be
installed. Do not use aftermarket sleeving. Do not re-adhere loose sleeving material.
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any
foreign material from the connector retaining clip area before separating from the tube. Apply clean
engine oil to the end of the tube before inserting the tube into the connector.
- Do not use any tools. Use of tools may cause a deformity in the coupling components which can
cause fuel leaks.
NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. If servicing a liquid fuel tube, release the fuel system pressure. 2. Disconnect the battery ground
cable.
3. Compress the clip legs and push the clip into the quick connect coupling.
4. Separate the quick connect coupling from the tube.
Connect - Type IV
1. Inspect the quick connect coupling and the tube for damage. Remove any dirt or obstructions.
2. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that
the fuel tube is fully seated, pull on the
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Spring Lock Couplings > Page 3394
tube.
NOTE: Apply clean engine oil to O-ring seals.
Fully insert the male tube end in the quick connect coupling and push the clip downward to lock the
fuel tubes together.
3. Pull on the connection to make sure it is fully engaged.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Fuel Rail Pressure Transducer Sensor
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Fuel Rail Pressure Transducer Sensor > Page 3399
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Fuel Rail Pressure Transducer Sensor > Page 3400
View 151-5 (Engine, Front - 4.0L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Diagrams > Fuel Rail Pressure/Temperature Sensor > Page 3403
C435
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 3406
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Description and Operation > Page 3407
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Description and Operation
Fuel Pressure Pulsation Damper: Description and Operation
FUEL RAIL PULSE DAMPER
Typical Fuel Rail Pulse Damper
The fuel rail pulse damper is located on the fuel rail and reduces the 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 if the pulse damper diaphragm ruptures. The fuel rail pulse damper
should not be confused with a fuel pressure regulator; it does not regulate the fuel rail pressure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Fuel Pressure
Key on, engine off.................................................................................................................................
.............................................207-276 kPa (30-40 psi) Engine running.................................................
..................................................................................................................................207-276 kPa
(30-40 psi)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 3418
C4033
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control
Unit > Component Information > Locations > Page 3419
Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal and Installation
1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM)
electrical connector. 3. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3423
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair
Fuel Rail: Service and Repair
FUEL RAIL
Exploded View
Removal and Installation
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 can be ignited. Failure
to follow these instructions can result in personal injury.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Page 3427
- Fuel in the fuel system remains under high pressure, even when the engine is not running. Before
working on or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions can result in personal injury.
NOTE: During the repair or installation of new fuel-related components, cap, tape or otherwise
appropriately protect all liquid and vapor fuel openings to prevent the ingress of dirt or other
contamination. Remove caps, tape and other protective materials prior to installation.
1. Release the fuel system pressure. 2. Disconnect the fuel supply tube spring lock coupling. 3.
Detach the 2 positive crankcase ventilation (PCV) coolant hose retainers from the fuel rail stud
bolts and position the hose aside. 4. Disconnect the fuel rail pressure and temperature sensor
electrical connector and vacuum hose. 5. Disconnect the 8 fuel injector electrical connectors. 6.
Remove the fuel rail stud bolts.
- To install, tighten to 10 Nm (89 lb-in).
7. Remove the fuel rail and fuel injectors as an assembly from the intake manifold.
8. NOTE: The fuel injector clip can be reused if it is not damaged during removal. If the clip is
reused, the 2 sides of the clip should be squeezed
back into shape by placing it between index finger and thumb.
Remove the retaining clips and fuel injectors from the fuel rail.
9. CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary
O-ring seals can cause the fuel system
to leak. Do not reuse the O-ring seals.
Remove and discard the fuel injector O-ring seals.
10. To install, reverse the removal procedure.
- Lubricate the new upper and lower fuel injector O-ring seals with clean engine oil prior to
installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair
Fuel Supply Line: Service and Repair
FUEL LINES
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3431
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3432
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Service and Repair > Page 3433
Explorer/Mountaineer (Part 2)
Exploded View
Removal and Installation
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 can 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
servicing or disconnecting any of the fuel lines or fuel system components, the fuel system
pressure must be relieved to prevent accidental spraying of fuel, which can cause a fire hazard.
Failure to follow these instructions may result in personal injury.
CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine
clearances. It is therefore essential that absolute cleanliness is observed when working with these
components. Always install blanking plugs to any open orifices or tubes.
NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. With the vehicle in NEUTRAL, position it on hoist. 2. Release the fuel system pressure. 3.
Disconnect the battery ground cable. 4. Disconnect the spring lock coupling at the engine and the
vapor tube quick connect coupling at the purge valve. 5. Disconnect the quick connect coupling at
the fuel filter and the vapor tube quick connect coupling at the fuel tank. 6. Remove the
transmission. 7. Remove the fuel lines from the vehicle. 8. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair
Fuel Filler Hose: Service and Repair
FUEL TANK FILLER PIPE
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3438
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3439
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3440
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3441
All Vehicles (Part 2)
Exploded View
Removal and Installation
All vehicles
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.
NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel
openings shall be capped, taped or otherwise appropriately protected to prevent the ingress of dirt
or other contamination. All caps, tape and other protective materials shall be removed prior to
installation.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Open the fuel tank filler cap. 4. Remove the 3 bolts and the fuel tank filler cap.
- To install, tighten to 1 Nm (9 lb-in).
Explorer/Mountaineer
5. NOTE: Body panel and fuel door removed for clarity.
Depress the 2 tabs on the fresh air vent tube in the fuel filler door pocket and disconnect the fresh
air vent tube from the inner fenderwell.
All vehicles
6. Disconnect the fuel filler pipe vapor tube-to-fuel pressure sensor and vapor tube assembly quick
connect coupling. 7. Disconnect the rear axle vent hose. 8. Disconnect the dust separator hose. 9.
Loosen the fuel tank filler pipe hose clamp and disconnect the hose.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Service and Repair > Page 3442
- To install, tighten to 3 Nm (27 lb-in).
10. Remove the 2 bolts and the fuel tank filler pipe assembly.
- To install, tighten to 15 Nm (11 lb-ft).
11. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation
Fuel Gauge Sender: Description and Operation
FUEL PUMP (FP) MODULE
Typical Electronic Returnless Fuel Pump (FP) Module
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3446
Typical Mechanical Returnless Fuel Pump (FP) Module
The FP module 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.
FUEL PUMP (FP) MODULE AND RESERVOIR
The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check
valve that maintains the system pressure after the key has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3447
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3448
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3449
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3450
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3451
All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3452
4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Page 3453
4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair
Fuel Tank Mounting Straps: Service and Repair
FUEL TANK SUPPORT STRAPS
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3457
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3458
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3459
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting
Straps > Component Information > Service and Repair > Page 3460
All Vehicles (Part 2)
Exploded View
Removal and Installation
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on any
fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure
to follow these instructions may result in personal injury.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the 4 bolts, the nut
and the fuel tank skid plate.
- To install, tighten to 40 Nm (30 lb-ft).
Explorer/Mountaineer
3. Remove the driveshaft.
All vehicles
4. Using a suitable jack, support the fuel tank. 5. Remove the bolt and the fuel tank rear support
strap.
- To install, tighten to 48 Nm (35 lb-ft).
6. Remove the nut and the fuel tank front support strap.
- To install, tighten to 48 Nm (35 lb-ft).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions
Pressure Release Valve Solenoid: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3466
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3467
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3468
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3469
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3470
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3471
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3472
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3473
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3474
Pressure Release Valve Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3475
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3476
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3477
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3478
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3479
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3480
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3481
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Pressure
Release Valve > Pressure Release Valve Solenoid > Component Information > Diagrams > Diagram Information and
Instructions > Page 3482
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Description and Operation
Fuel Tank Unit: Description and Operation
FUEL PUMP (FP) MODULE
Typical Electronic Returnless Fuel Pump (FP) Module
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Description and Operation > Page 3486
Typical Mechanical Returnless Fuel Pump (FP) Module
The FP module 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.
FUEL PUMP (FP) MODULE AND RESERVOIR
The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check
valve that maintains the system pressure after the key has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Diagrams
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Diagrams > Page 3490
Fuel Temperature Sensor: Description and Operation
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Diagrams > Page 3491
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation
Idle Speed/Throttle Actuator - Electronic: Description and Operation
IDLE AIR CONTROL (IAC) VALVE
NOTE: The IAC valve assembly is not adjustable and cannot be cleaned, also some IAC valves are
normally open and others are normally closed. Some IAC valves require engine vacuum to
operate.
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
The PCM uses the IAC valve assembly to control:
- no touch start
- cold engine fast idle for rapid warm-up
- idle (corrects for engine load)
- stumble or stalling on deceleration (provides a dashpot function)
- over-temperature idle boost
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3498
C282
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3499
Inertia Fuel Shutoff Switch: Description and Operation
INERTIA FUEL SHUTOFF (IFS) SWITCH
Typical Inertia Fuel Shutoff (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shutoff 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's Literature for the location of the IFS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 3500
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the
IFS switch
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair
Intake Air Duct: Service and Repair
AIR CLEANER OUTLET PIPE
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Page 3504
Exploded View
Removal and Installation
Vehicles equipped with a 4.0L SOHC engine
1. Detach the wiring harness retainer from the air cleaner outlet pipe.
Vehicles equipped with a 4.6L (3V) engine
2. Disconnect the brake booster vacuum hose from the air cleaner outlet pipe.
All vehicles
3. Disconnect the crankcase breather hose from the air cleaner outlet pipe. 4. Loosen the clamps
and remove the air cleaner outlet pipe. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3508
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Control Unit > Component Information > Locations
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3513
C4033
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 3514
Fuel Pump Control Unit: Service and Repair
FUEL PUMP DRIVER MODULE (FPDM)
Removal and Installation
1. Remove the RH rear quarter trim panel. 2. Disconnect the fuel pump driver module (FPDM)
electrical connector. 3. Remove the bolts and the FPDM.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3518
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3522
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3527
C2040
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3528
Accelerator Pedal Position Sensor: Description and Operation
ACCELERATOR PEDAL POSITION (APP) SENSOR
The APP sensor is an input to the powertrain control module (PCM) and is used to determine the
torque demand. There are 3 pedal position signals in the sensor. Signal 1, APPS1, has a negative
slope (increasing angle, decreasing voltage) and signals 2 and 3, APPS2 and APPS3, both have a
positive slope (increasing angle, increasing voltage). During normal operation APPS1 is used as
the indication of pedal position by the strategy. The 3 pedal position signals make sure the PCM
receives a correct input even if 1 signal has a concern. There are 2 reference voltage circuits and 2
signal return circuits for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3532
C128
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3533
Air Flow Meter/Sensor: Description and Operation
MASS AIR FLOW (MAF) SENSOR
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire (and IAT
Sensor Wire Where Applicable) Terminals
Typical Mass Air Flow (MAF) Sensor
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3534
Typical Drop-in Mass Air Flow (MAF) Sensor
The 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 the ambient temperature as measured by a constant cold wire. The current required to
maintain the temperature of the hot wire is proportional to the mass air 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. This
input is also used in determining transmission electronic pressure control (EPC), shift and torque
converter clutch scheduling.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly. Most MAF sensors have integrated bypass technology with an integrated intake air
temperature (IAT) sensor. The hot wire electronic sensing element must be replaced as an
assembly. Replacing only the element may change the air flow calibration.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3535
Air Flow Meter/Sensor: Service and Repair
MASS AIR FLOW (MAF) SENSOR
Removal and Installation
1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolts and the
MAF sensor.
- To install, tighten to 2 Nm (18 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail Pressure
Transducer Sensor
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail Pressure
Transducer Sensor > Page 3540
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Fuel Rail Pressure
Transducer Sensor > Page 3541
View 151-5 (Engine, Front - 4.0L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Fuel Rail
Pressure/Temperature Sensor > Page 3544
C435
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail
Pressure (FRP) Sensor
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor
FUEL RAIL PRESSURE (FRP) SENSOR
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure.
The electrical resistance of a strain gauge increases as pressure increases, and the resistance
decreases as the 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail
Pressure (FRP) Sensor > Page 3547
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Page
3548
Fuel Pressure Sensor/Switch: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams
C173
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 3552
Fuel Temperature Sensor: Description and Operation
FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR
Typical Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 3553
Fuel Temperature Sensor: Service and Repair
FUEL RAIL PRESSURE AND TEMPERATURE SENSOR
Removal and Installation
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 tubes or fuel system components, the fuel system
pressure must be relieved. Failure to follow these instructions may result in personal injury.
1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel
rail pressure and temperature sensor electrical connector. 4. Disconnect the fuel rail pressure and
temperature sensor vacuum hose connector. 5. Remove the 2 bolts and the fuel rail pressure and
temperature sensor.
- To install, tighten to 6 Nm (53 lb-in).
6. To install, reverse the removal procedure.
- Inspect the O-ring seal and install a new O-ring seal if necessary.
- Lubricate the O-ring seal with clean engine oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3557
C282
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3558
Inertia Fuel Shutoff Switch: Description and Operation
INERTIA FUEL SHUTOFF (IFS) SWITCH
Typical Inertia Fuel Shutoff (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shutoff 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's Literature for the location of the IFS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3559
Inertia Fuel Shutoff Switch: Service and Repair
INERTIA FUEL SHUTOFF (IFS) SWITCH
Removal and Installation
1. NOTE: The front passenger door frame scuff plate is retained only by internal metal clips.
Remove the front passenger door frame scuff plate.
2. NOTE:
- The front passenger door side interior kick panel is retained only by internal metal clips.
- It may be necessary to reposition the lower end of the door jam weather stripping to remove the
front passenger door side interior kick panel.
Remove the front passenger side interior kick panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. 4. Remove the bolts and the
IFS switch
- To install, tighten to 2 Nm (18 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3563
C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body (ETB) Position Sensor > Page 3566
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3567
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3568
Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair
Throttle Body: Service and Repair
THROTTLE BODY
Removal and Installation
CAUTION: The throttle body must be removed from the vehicle to be cleaned. Do not hold the
throttle plate open with any object that could scratch the bore or plate while servicing or cleaning
the throttle body.
1. Remove the air cleaner outlet pipe. 2. Disconnect the electronic throttle control electrical
connector. 3. Disconnect the throttle position (TP) sensor electrical connector. 4. Remove the bolts,
the throttle body (TB) and the TB gasket. Discard the gasket.
- To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3575
C189
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor
Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor
ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR
The ETB position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB
position signals are required for increased monitoring. The first ETB position sensor signal (TP1)
has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a
positive slope (increasing angle, increasing voltage). During normal operation the negative slope
ETB position sensor signal (TP1) is used by the control strategy as the indication of throttle
position. The 2 ETB position sensor signals make sure the PCM receives a correct input even if 1
signal has a concern. There is 1 reference voltage circuit and 1 signal return circuit for the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body (ETB) Position Sensor > Page 3578
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
THROTTLE POSITION (TP) SENSOR
Typical TP Sensor
The TP sensor 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 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. The operating 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)
- throttle angle rate
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 3579
Throttle Position Sensor: Service and Repair
THROTTLE POSITION (TP) SENSOR
Removal
Vehicles equipped with a 4.6L (3V) engine 1. Remove the air cleaner outlet pipe.
2. Remove the bolts and position the heated positive crankcase ventilation (PCV) fitting and hoses
aside.
- Remove and discard the O-ring seal.
All vehicles 3. Disconnect the throttle position (TP) sensor electrical connector.
4. CAUTION: Failure to remove the TP sensor screws in the following manner will result in damage
to the screws. First loosen the screws
1-2 full turns using a hand tool and then use a suitable high-speed driver to complete the removal.
Remove and discard the 2 screws and the TP sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 3580
Installation
All vehicles
1. CAUTION:
- Do not reuse the TP sensor and screws. A new TP sensor and screws must be installed.
- Do not use a high-speed driver to install the new screws or damage to the TP sensor can occur.
NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor
is aligned with the radial locator hole on the throttle body.
Position the new TP sensor and install the 2 new screws. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
Vehicles equipped with a 4.6L (3V) engine
3. Install a new O-ring seal, position the heated PCV fitting and install the bolts. 4. Install the air
cleaner outlet pipe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Induction Control Actuator: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's P2000-P2008/P2015/P2020 Set
Variable Induction Control Actuator: Customer Interest Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set
TSB 06-7-10
04/17/06
MIL ON WITH DTC P2004 THROUGH P2008, P151A, P2015, P2020 - 4.6L 3V
FORD: 2005-2006 Mustang 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
This article supersedes TSB 05-25-15 to update the vehicle model years.
ISSUE Some 2005-2006 Mustang GT, 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport
Trac vehicles may exhibit the malfunction indicator lamp (MIL) on, with diagnostic trouble codes
(DTCs) P2004 through P2008, P151A, P2015, and P2020. All of these codes are associated with
the charge motion control valve (CMCV), actuator motor, and/or linkage concerns.
ACTION Refer to the following Service Procedure to determine if a CMCV Actuator Kit should be
installed.
SERVICE PROCEDURE
1. Does the vehicle exhibit DTC P2004, P2005, P2006, and/or P2007 (stuck CMCV
motor/linkages)?
a. If so, visually inspect CMCV linkages to ensure they are free of interference from improper wire
routings or foreign objects. If there is interference, resolve interference as needed. If there is no
interference or disconnected/damaged wiring to CMCV actuator proceed to Step 2.
b. If not, proceed to Step 2.
2. Remove intake manifold from engine as outlined in the Workshop Manual, Section 303-01.
Position the intake manifold on a clean flat work surface, with bottom side up as shown in the
CMCV Actuator Kit instruction sheet. Take care to prevent debris from entering the runner ports.
CAUTION
DO NOT REST THE MANIFOLD ON THE INTAKE MANIFOLD FLANGE, AS IRREPARABLE
DAMAGE MAY OCCUR TO THE CMCV PLATES.
NOTE
VISUALLY INSPECT THAT ALL CMCV PLATES ARE INTACT. BENT PLATES OR OTHERWISE
DAMAGED COMPONENTS WILL REQUIRE ENTIRE MANIFOLD REPLACEMENT (REFER TO
FIGURE 1 IN CMCV ACTUATOR KIT INSTRUCTION SHEET).
3. Disconnect the CMCV linkages from actuator motor by removing the two (2) clips (Figure 1).
Discard clips.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Induction Control Actuator: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's P2000-P2008/P2015/P2020 Set > Page 3590
4. Rotate each CMCV shaft (right hand and left hand) by hand, to verify that the system does not
stick or bind. The shafts should rotate freely and any sticking or binding will require replacement of
the entire intake manifold.
5. If the components inspected in Steps 1, 2, and 3 are OK, then replace CMCV actuator motor by
following procedure included in the service kit.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060710A 2005-2006 Mustang 4.6L 1.8 Hrs.
3V: Inspect CMCV plates, Replace Intake Manifold, Includes Time To Check For Diagnostic
Trouble Codes, Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A,
9531A, 9424A, 9926A, 12650D24, 12650D35)
060710B 2005-2006 Mustang 4.6L 1.7 Hrs
3V: Inspect CMCV plates, Replace CMCV, Includes Time To Check For Diagnostic Trouble Codes,
Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A, 9531A, 9424A,
9926A, 12650D24, 12650D35)
06071OC 2006 Explorer, 1.9 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace Intake Manifold
Includes Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do
Not Use With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 12650D24, 12650D35)
060710D 2006 Explorer, 1.8 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace CMCV, Includes
Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do Not Use
With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 1650D24, 12650D35)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > Customer Interest for Variable
Induction Control Actuator: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's P2000-P2008/P2015/P2020 Set > Page 3591
DEALER CODING
CONDITION
BASIC PART NO. CODE
9G730 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Variable Induction Control Actuator: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's P2000-P2008/P2015/P2020 Set
Variable Induction Control Actuator: All Technical Service Bulletins Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set
TSB 06-7-10
04/17/06
MIL ON WITH DTC P2004 THROUGH P2008, P151A, P2015, P2020 - 4.6L 3V
FORD: 2005-2006 Mustang 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
This article supersedes TSB 05-25-15 to update the vehicle model years.
ISSUE Some 2005-2006 Mustang GT, 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport
Trac vehicles may exhibit the malfunction indicator lamp (MIL) on, with diagnostic trouble codes
(DTCs) P2004 through P2008, P151A, P2015, and P2020. All of these codes are associated with
the charge motion control valve (CMCV), actuator motor, and/or linkage concerns.
ACTION Refer to the following Service Procedure to determine if a CMCV Actuator Kit should be
installed.
SERVICE PROCEDURE
1. Does the vehicle exhibit DTC P2004, P2005, P2006, and/or P2007 (stuck CMCV
motor/linkages)?
a. If so, visually inspect CMCV linkages to ensure they are free of interference from improper wire
routings or foreign objects. If there is interference, resolve interference as needed. If there is no
interference or disconnected/damaged wiring to CMCV actuator proceed to Step 2.
b. If not, proceed to Step 2.
2. Remove intake manifold from engine as outlined in the Workshop Manual, Section 303-01.
Position the intake manifold on a clean flat work surface, with bottom side up as shown in the
CMCV Actuator Kit instruction sheet. Take care to prevent debris from entering the runner ports.
CAUTION
DO NOT REST THE MANIFOLD ON THE INTAKE MANIFOLD FLANGE, AS IRREPARABLE
DAMAGE MAY OCCUR TO THE CMCV PLATES.
NOTE
VISUALLY INSPECT THAT ALL CMCV PLATES ARE INTACT. BENT PLATES OR OTHERWISE
DAMAGED COMPONENTS WILL REQUIRE ENTIRE MANIFOLD REPLACEMENT (REFER TO
FIGURE 1 IN CMCV ACTUATOR KIT INSTRUCTION SHEET).
3. Disconnect the CMCV linkages from actuator motor by removing the two (2) clips (Figure 1).
Discard clips.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Variable Induction Control Actuator: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's P2000-P2008/P2015/P2020 Set >
Page 3597
4. Rotate each CMCV shaft (right hand and left hand) by hand, to verify that the system does not
stick or bind. The shafts should rotate freely and any sticking or binding will require replacement of
the entire intake manifold.
5. If the components inspected in Steps 1, 2, and 3 are OK, then replace CMCV actuator motor by
following procedure included in the service kit.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060710A 2005-2006 Mustang 4.6L 1.8 Hrs.
3V: Inspect CMCV plates, Replace Intake Manifold, Includes Time To Check For Diagnostic
Trouble Codes, Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A,
9531A, 9424A, 9926A, 12650D24, 12650D35)
060710B 2005-2006 Mustang 4.6L 1.7 Hrs
3V: Inspect CMCV plates, Replace CMCV, Includes Time To Check For Diagnostic Trouble Codes,
Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A, 9531A, 9424A,
9926A, 12650D24, 12650D35)
06071OC 2006 Explorer, 1.9 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace Intake Manifold
Includes Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do
Not Use With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 12650D24, 12650D35)
060710D 2006 Explorer, 1.8 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace CMCV, Includes
Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do Not Use
With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 1650D24, 12650D35)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Variable Induction Control Actuator: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's P2000-P2008/P2015/P2020 Set >
Page 3598
DEALER CODING
CONDITION
BASIC PART NO. CODE
9G730 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > Page 3599
C1442
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > Page 3600
Variable Induction Control Actuator: Description and Operation
INTAKE MANIFOLD TUNING VALVE (IMTV)
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.
The IMTV 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 is not energized below approximately 2,600 RPM. The shutter is in the
closed position not allowing airflow blend to occur in the intake manifold. The motorized unit is
energized above approximately 2,600 RPM. The motorized unit is 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > Page 3601
Variable Induction Control Actuator: Service and Repair
CHARGE MOTION CONTROL VALVE (CMCV)
Removal
1. Remove the intake manifold.
2. NOTE: Do not disconnect the linkages at the intake manifold unless a new intake manifold is
being installed.
Remove and discard the 2 E-clips and disconnect the charge motion control valve (CMCV)
linkages from the CMCV.
3. NOTE: Bent shaft or damaged components will require a new intake manifold.
Rotate each CMCV shaft by hand to verify that they do not stick or bind.
4. Remove the 3 bolts and the CMCV.
Installation
1. Position the CMCV and loosely install the 3 bolts.
- Do not tighten the bolts at this time.
2. Rotate each CMCV shaft so that the plates are in the closed position.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Technical Service Bulletins > Page 3602
3. Install the RH and LH CMCV plate alignment locks. 4. Connect the RH and LH CMCV linkages
to the CMCV and install 2 new E-clips. 5. Verify that the CMCV plate alignment locks are still
correctly located and tighten the 3 CMCV bolts.
- Tighten to 10 Nm (89 lb-in).
6. Remove the RH and LH alignment locks. 7. Install the intake manifold. 8. Carry out the KOEO
self test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications > Page 3607
Firing Order: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Number One Cylinder: Locations
Firing order...........................................................................................................................................
...........................................................1-3-7-2-6-5-4-8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Camshaft Position Sensor 1 > Page 3616
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor
C180
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Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor > Page 3619
C1366
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Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Camshaft Position Sensor > Page 3620
C1367
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Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3621
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 3622
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3626
Crankshaft Position Sensor: Diagrams
C101
C1120
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3627
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3628
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 3629
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1
C111
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3635
C112
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3636
C113
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Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3637
C114
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Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3638
Ignition Coil: Diagrams
C111
C112
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3639
C113
C114
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Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3640
C115
C116
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Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3641
C117
C118
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Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3642
C1196
C174
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Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1 > Page 3643
C194
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 3644
Ignition Coil: Description and Operation
COIL ON PLUG (COP)
Typical Coil On Plug (COP)
The COP ignition operates similar to a standard coil pack ignition except each plug has one coil per
plug. The COP has 3 different modes of operation: engine crank, engine running, and CMP failure
mode effects management (FMEM).
COIL PACK
Typical Four-Tower Coil Pack
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 3645
Typical Six-Tower Coil Pack
The PCM provides a grounding switch for the coil primary circuit. When the switch is closed,
voltage is applied to the coil primary circuit. This creates a magnetic field around the primary coil.
The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the
secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark
plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next
time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine
firing order.
Coil packs come in 4-tower, 6-tower horizontal and series 5 6-tower models. Two adjacent coil
towers share a common coil and are called a matched pair. For 6-tower coil pack (6 cylinder)
applications, the matched pairs are 1 and 5, 2 and 6, and 3 and 4. For 4-tower coil pack (4 cylinder)
applications, the matched pairs are 1 and 4, and 2 and 3.
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Page 3646
Ignition Coil: Service and Repair
IGNITION COIL-ON-PLUG
Exploded View
Removal and Installation
1. Disconnect the ignition coil electrical connectors. 2. Remove the ignition coil bolts.
- To install, tighten to 5 Nm (44 lb-in).
3. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease
removal.
Remove the ignition coils.
4. To install, reverse the removal procedure.
- Apply a light film of brake caliper grease to the inside of the coil boots before installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information >
Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information >
Locations > Page 3650
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams
C108
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Diagrams > Page 3654
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Relay > Component Information > Locations > Page 3659
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3665
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor
C180
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Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3668
C1366
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Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3669
C1367
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 3670
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION (CMP) SENSOR
Typical Synchronizer Hall-Effect CMP Sensor
Typical Variable Reluctance CMP Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the
second sensor to identify the position of the camshaft on bank 2 as an input to the PCM.
There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor and the 2-pin
connector variable reluctance type sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 3671
Camshaft Position Sensor: Service and Repair
REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor
Removal and Installation
RH side
1. Remove the air cleaner outlet pipe.
Both sides
2. Disconnect the camshaft position (CMP) sensor electrical connector. 3. Remove the bolt and the
CMP sensor.
- To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3675
Crankshaft Position Sensor: Diagrams
C101
C1120
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3676
Crankshaft Position Sensor: Description and Operation
CRANKSHAFT POSITION (CKP) SENSOR
Typical Crankshaft Position (CKP) Sensor
The 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 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 10-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 for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid deceleration between teeth.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3677
Crankshaft Position Sensor: Service and Repair
CRANKSHAFT POSITION (CKP) SENSOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 3678
Removal and Installation
1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3.
Disconnect the A/C compressor coil electrical connector. 4. Detach the battery cable retainer from
the A/C compressor stud bolts. 5. Remove the nut and detach the A/C tube bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Remove the stud bolts and position the A/C compressor aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Remove the bolt and
the CKP sensor.
- To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
Ignition Switch Lock Cylinder: Service and Repair
IGNITION LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the ignition lock cylinder. 2. To install, reverse the removal procedure.
- Lubricate the ignition lock cylinder during installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams
C108
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Diagrams > Page 3686
Knock Sensor: Description and Operation
KNOCK SENSOR (KS)
Two Types Of Knock Sensor (KS)
The KS 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions
Spark Plug: Technical Service Bulletins Ignition System - Spark Plug Removal Instructions
TSB 08-7-6
04/14/08
SPARK PLUG REMOVAL INSTRUCTIONS - 4.6L 3V/5.4L 3V16.8L 3V
FORD: 2005-2008 Mustang 2004-2008 F-150 2005-2008 Expedition, F-Super Duty 2006-2008
Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac
LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part
List.
ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and
Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and
2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and
F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This
may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected
engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07.
ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and
extract broken spark plugs.
SERVICE PROCEDURE
The engine build date can be read on the left hand cam cover information sticker.
To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before
removal is attempted.
CAUTION
DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT
ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE
SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS
COULD BE DAMAGED.
Spark Plug Removal Procedure
1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and
surrounding valve cover area with compressed air.
2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor
Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 - 3/4
teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to
the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark
plug back and forth at this point.
NOTE
COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR
TUNE-UP CLEANER PRODUCT - USE AT ROOM TEMPERATURE AND SHAKE WELL.
CAUTION
EXCESSIVE MOTORCRAFT(R) CARBURETOR TUNE-UP CLEANER, OR REPEATING THE
PROCESS SEVERAL TIMES WITH TOO MUCH CLEANER FLUID, COULD INTRODUCE
ENOUGH LIQUID VOLUME TO HYDRO-LOCK THE ENGINE.
CAUTION
DO NOT USE AIR OR POWER TOOLS FOR SPARK PLUG REMOVAL. SPARK PLUGS MUST
ONLY BE REMOVED WITH HAND TOOLS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3691
3. Tighten, and then loosen the spark plug, working the plug back and forth. Some screeching and
high effort may be noticed. The expected removal torque is about 33 lb-ft (45 N.m). Repeat the
back and forth turning as needed until turning effort is reduced, and remove the spark plugs.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (Figure 1)
Separated/Broken Spark Plug Removal
If the spark plug separates after following the Spark Plug Removal Procedure, it will fail in one of
three modes. Refer to the appropriate removal procedure as required.
a. Mode 1: The ground electrode shield is left behind as an empty shell. (Figure 2)
b. Mode 2: The entire porcelain insulator and ground electrode shield remains in the cylinder head.
(Figure 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3692
c. Mode 3: The upper section of porcelain broke off with remaining porcelain left inside the ground
shield. (Figure 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3693
Flowchart of procedure. (Figure 5)
Mode 1 Procedure:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3694
Use Rotunda special service tool 303-1203 to remove an empty ground electrode shield from the
cylinder head. (Figure 6)
NOTE
THIS TOOL IS ONLY DESIGNED TO WORK WITH AN EMPTY GROUND ELECTRODE SHIELD.
IF PORCELAIN REMAINS, PROCEED TO MODE 2 OR 3 REMOVAL.
1. Modify vacuum cap to a 3/8" (10 mm) length for each ground electrode shield that needs to be
removed. (Figure 7)
2. Use the installation rod (J) provided with service tool 303-1203 update to install the modified
vacuum cap. Push the cap into the ground shield down to the electrode strap. This will plug and
protect the combustion chamber from contamination. (Figure 7)
3. Thread-tap the ground electrode shield using a 9.0 x 1.0 mm plug tap (tap profile is about 3-4
reduced diameter threads on the tip end).
a. Coat the end of the tap with general purpose grease. (Figure 8)
b. Turn the tap about 3 to 4 turns into the ground electrode shield. Back the tap up frequently to
break chips and avoid cut material from coiling-up in the spark plug well. A tap socket adaptor (K)
is provided with service tool 303-1203 update to connect the tap to a 3/8" socket
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3695
drive.
CAUTION
DO NOT ATTEMPT TO REMOVE THE GROUND ELECTRODE SHIELD WITH THE TAP AND
WRENCH. THE TAP MAY BREAK IF THIS IS ATTEMPTED.
4. Thread Rotunda special service tool 303-1203 into the ground electrode shield. (Figure 9)
a. Install the stepped end of the tool pilot bushing into the spark plug well ensuring it bottoms out.
b. Screw the center shank into the ground electrode shield. Do not over tighten the shank, to
prevent thread stripping.
c. Install the nylon washer and jack nut until finger tight.
d. Turn the jack nut until the ground electrode is freed from the cavity and withdraw the tool
assembly.
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP.
Mode 2 Procedure:
1. Add an additional 1/2 teaspoon Motorcraft® Carburetor Tune-Up Cleaner fluid into spark plug
well and allow 15 minutes of soak time.
2. Using long-reach nose pliers grasp and remove the porcelain with an up and down motion taking
care not to fracture the porcelain.
3. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Mode 3 Procedure:
CAUTION
DO NOT DRIVE PORCELAIN DOWN INTO THE GROUND SHIELD WITH A PUNCH AS
FRAGMENTS MAY ENTER THE COMBUSTION CHAMBER.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3696
Use Rotunda special service tool kit 303-1398 to remove porcelain broken inside the ground
electrode shield. (FIGURE 10)
Porcelain Removal - Preparation
CAUTION
THE ENGINE AND THE BONDING ADHESIVE MUST BE ROOM TEMPERATURE OF 70 °F (21
°C) OR HIGHER FOR PROPER CURE AND BOND STRENGTH. VERIFY EXPIRATION DATE OF
ADHESIVE.
CAUTION
DO NOT REUSE PINS. THIS ENSURES THE CORRECT SURFACE CHARACTERISTICS FOR
BONDING.
1. Remove any remaining electrode material from broken porcelain with long nose reach pliers.
2. Spray Motorcraft® Metal Brake Parts Cleaner into the porcelain hole for 2-4 seconds using the
straw nozzle supplied with the brake cleaner can.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3697
3. Insert a pin (A) into the collet (B). Screw the collet onto the threaded rod (C). Install the
assembled collet, pin, and threaded rod into the steel tool pilot (F). (Figures 11 and 12)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3698
4. Retract the collet and pin into the steel tool pilot, protecting the pin. (Figures 13 and 14)
NOTE
PIN TIP DAMAGE OR BENT PINS WILL PREVENT INSERTION INTO THE PORCELAIN.
5. Insert the completed assembly into the spark plug well and fully engage the pin into the
porcelain. (Figure 15)
6. Spray Motorcraft(R) Metal Brake Parts Cleaner 2-4 seconds between the spark plug well and
steel tool pilot. The steel tool pilot must be lifted up approximately 1/2" to allow brake cleaner to
flood the porcelain and pin.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3699
7. Scrub the porcelain inside diameter by moving the threaded rod up and down vigorously. Take
care making sure the pin does not disengage the porcelain. (Figure 16).
8. Repeat Steps 6 and 7.
9. Remove the tool assembly. Again flood the porcelain with Motorcraft(R) Metal Brake Parts
Cleaner for 2-4 seconds, then blow out the entire spark plug well and porcelain with dry
compressed air.
NOTE
CLEAN AND DRY COMPONENTS ARE KEY TO BONDING THE PIN TO THE PORCELAIN.
10. Repeat Steps 1-9 to prepare remaining porcelain fragments as needed.
11. Disassemble the collet and pin from the threaded rod. Dry the tools thoroughly with dry
compressed air.
Porcelain Removal - Bonding Process
CAUTION
USE CARE TO PREVENT BONDING AGENT FROM CONTACTING THREADS IN CYLINDER
HEAD.
NOTE
WORKING TIME LIMIT OF LOCTITE(R) 638(TM) RETAINING COMPOUND IS 5 MINUTES.
1. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to opposite sides of a clean and dry
applicator (H). Excessive amounts of Loctite(R) 638(TM) are being used if it drips off the applicator.
(Figure 17)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3700
2. Insert applicator into the porcelain and move applicator up and down 1/2" (13 mm) while turning
to spread the Loctite® 638TM on the inside of the porcelain. (Figure 18).
3. Add additional Loctite(R) 638(TM), repeating Steps 1 and 2.
4. Clean the applicator with Motorcraft(R) Metal Brake Parts Cleaner before the bonding agent
starts to cure.
5. Reassemble a dry and clean collet and pin assembly.
6. Apply two 3/4" (19 mm) long stripes of Loctite(R) 638(TM) to the pin. Excessive amounts of
Loctite® 638TMare being used if it drips off the pin.
7. Retract the collet and pin into the steel tool pilot to protect the Loctite(R) 638(TM) coated pin.
8. Insert the completed assembly into spark plug well and fully engage the pin into the porcelain
with a twisting motion to spread the bonding agent.
9. Add additional Loctite® 638TM, repeating Steps 6-8.
10. Leave the pin fully inserted in the porcelain while the adhesive cures. Replace the steel tool
pilot with the aluminum alignment sleeve (G), Figure 9, to support the threaded rod while the
adhesive cures if additional porcelain fragments are present in other cylinders. (Figure 19).
CAUTION
A MINIMUM 1 HOUR CURING TIME AT 70 °F (21 °C) DEGREES IS REQUIRED BEFORE
EXTRACTION IS ATTEMPTED.
11. Allow the Loctite(R) 638(TM) to cure for a minimum of one hour at 70 °F (21 °C).
12. Repeat the bonding process for remaining cylinders as needed.
Porcelain Removal - Extraction
1. After a minimum of one hour curing at 70 °F (21 °C), install the steel pilot tool over the threaded
rod.
2. Install the washer and jack nut until finger tight against the tool pilot bushing.
CAUTION
ONLY THE STEEL PILOT TOOL IS ACCEPTABLE FOR USE IN PORCELAIN REMOVAL.
3. While holding the end of the threaded rod with a wrench, tighten the jack nut until the porcelain is
free of the ground electrode.
4. Refer to Mode 1 Procedure to remove the remaining ground electrode shield from the cylinder
head.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Ignition System - Spark Plug Removal Instructions > Page 3701
NOTE
NEW PLUGS SHOULD BE INSTALLED USING A FILM COATING OF MOTORCRAFT® HIGH
TEMPERATURE NICKEL ANTI-SEIZE LUBRICANT ON THE GROUND ELECTRODE SHIELD.
DO NOT COAT THE ELECTRODE STRAP. (FIGURE 7)
Porcelain Removal - Pin Slipped Out
In the unlikely event that the pin does not remove the broken porcelain, this process can be
repeated.
Key elements to success are:
^ Clean and dry porcelain
^ Sufficient Loctite® 638TM Retaining Compound spread uniformly
^ Loctite(R) 638(TM) cure time and temperature
^ Preventing the threaded rod from rotating while removing the porcelain
Replacement Supplies
Replacement kit components and additional kit consumables (Loctite(R) 638TM Retaining
Compound and pins) can be obtained by calling 1-800-ROTUNDA, Option 5.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions 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
MT080706 Claim Labor As Actual Actual
Time Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
12405 01
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > General Specifications
Spark Plug: Specifications General Specifications
Item.......................................................................................................................................................
..............................................................Specification
Spark plug gap (not adjustable)............................................................................................................
.....................................1.02-1.28 mm 0.040-0.050 in)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > General Specifications > Page 3704
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3705
Spark Plug: Application and ID
Spark Plug Type ..................................................................................................................................
....................................................................... PZT1F
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3706
Spark Plug: Testing and Inspection
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.
^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
^ Clean the spark plug.
2. Check for oil fouling.
^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
^ Correct the oil leak concern.
^ Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
^
Clean the spark plug.
4. Inspect for normal burning.
^ Check for light tan or gray deposits on the firing tip.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3707
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. ^
Install a new spark plug.
6. Inspect for overheating, identified by white or light gray spots and with bluish-burnt appearance
of electrodes. This is caused by engine
overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low
fuel pump pressure or incorrect ignition timing. ^
Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
^ Clean the spark plug.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3708
Spark Plug: Service and Repair
SPARK PLUGS
Exploded View
Removal and Installation
1. Disconnect the ignition coil electrical connectors. 2. Remove the ignition coil bolts.
- To install, tighten to 5 Nm (44 lb-in).
3. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease
removal.
Remove the ignition coils.
4. NOTE:
- Use compressed air to remove any foreign material from the spark plug well before removing the
spark plugs.
- If an original spark plug is re-used, make sure it is installed in the same cylinder from which it was
taken. New spark plugs can be used in any cylinder.
Remove the spark plugs. To install, tighten to 34 Nm (25 lb-ft).
5. CAUTION: The spark plug gap is NOT adjustable. Damage can occur to the ceramic if the spark
plug is adjusted. Install a new spark
plug if the gap is out of specification.
Inspect the spark plugs. Install new spark plugs as necessary.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 3709
6. To install, reverse the removal procedure.
- Apply a light film of brake caliper grease to the inside of the coil boots before installation.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Information > Diagrams > Diagram Information and Instructions > Page 3717
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3718
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3719
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3720
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3721
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3722
Symbols Part 3
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3723
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3724
Symbols Part 5
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3725
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Information > Diagrams > Diagram Information and Instructions > Page 3727
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3728
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
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3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3730
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3732
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3733
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Brake Shift Interlock Actuator
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
brake shift lock actuator electrical connector.
3. Remove the screw and the brake shift lock actuator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair > Page 3737
Installation
1. Install the brake shift lock actuator.
2. Connect the brake shift lock actuator electrical connector.
3. Install the front floor console. For additional information, refer to Console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3742
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3743
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3744
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3745
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3746
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3747
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3748
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3749
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3750
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3751
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3752
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3753
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3754
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3755
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3756
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3757
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3758
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3763
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3764
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3765
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3766
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3767
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3768
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3769
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3770
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3771
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3772
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3773
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3774
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3775
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3776
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3777
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3778
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3779
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Service and Repair
Transfer Case Actuator: Service and Repair
Transfer Case Shift Motor
Material
Removal and Installation
1. With the ignition ON, press the 4x4 HIGH button on the mode select switch (MSS). 2. With the
transmission in the NEUTRAL position, raise and support the vehicle. For additional information,
refer to Maintenance/Service and
Repair.
3. Disconnect the transfer case shift motor harness connector.
4. Remove the bracket bolt and transfer case shift motor mounting bolts and remove the transfer
case shift motor.
5. To install, reverse the removal procedure.
^ Apply a coat of Multi-Purpose Grease to the transfer case shift motor bolts.
^ Tighten to 10 Nm (89 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Diagrams
C2260
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: Customer Interest Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page
3803
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page
3808
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page
3809
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page
3810
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability
Issues
Control Module: All Technical Service Bulletins Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability
Issues > Page 3816
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In
TCM
Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In
TCM > Page 3821
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In
TCM > Page 3822
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In
TCM > Page 3823
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Locations
View 151-9 (Automatic Transmission)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Locations > Page 3828
Control Module: Diagrams
C281A
C281B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Locations > Page 3829
Control Module: Service and Repair
Four Wheel Drive (4WD) Control Module
Four Wheel Drive (4WD) Control Module
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Open the
glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4.
Disconnect the electrical connectors. 5. Remove the four wheel drive (4WD) control module. 6. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions
Brake Switch - TCC: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3836
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3837
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3838
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3839
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3840
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3841
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3842
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3843
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3844
Brake Switch - TCC: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3845
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3846
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3847
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3848
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3849
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3850
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3851
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 3852
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Page 3853
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Overdrive Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3858
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3859
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3860
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3861
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3862
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3863
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3864
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3865
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3866
Overdrive Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3867
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3868
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3869
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3870
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3871
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3872
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3873
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 3874
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions
Throttle Position Sensor/Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3879
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3880
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3881
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3882
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3883
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3884
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3885
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3886
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3887
Throttle Position Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3888
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3889
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3890
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3891
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3892
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3893
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3894
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3895
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions
Transmission Mode Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3900
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3901
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3902
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3903
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3904
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3905
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3906
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3907
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3908
Transmission Mode Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3909
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3910
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3911
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3912
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3913
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3914
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3915
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 3916
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation > Transmission Control (TC) Switch
Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch
Transmission Control (TC) Switch
The transmission control (TC) switch is a momentary contact switch located on the selector lever
knob. Pushing the TC switch will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the
instrument panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation > Transmission Control (TC) Switch > Page 3919
Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS)
TRANSMISSION CONTROL SWITCH (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3920
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Removal
1. Remove the transmission selector lever knob.
2. Remove the transmission control switch from the knob.
Installation
1. Install the transmission control switch into the knob.
2. Install the transmission selector lever knob.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3925
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3926
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3927
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3928
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3929
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3930
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3931
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3932
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3933
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3934
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3935
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3936
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3937
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3938
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3939
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3940
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3941
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 3942
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3947
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3948
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3949
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3950
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3951
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3952
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3953
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3954
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3955
Transmission Speed Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3956
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3957
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3958
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3959
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3960
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3961
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3962
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3963
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3964
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 3965
C164
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3970
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3971
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3972
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3973
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3974
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3975
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3976
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3977
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3978
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3979
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3980
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3981
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3982
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3983
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3984
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3985
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 3986
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 3991
C284
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 3992
Four Wheel Drive Selector Switch: Service and Repair
Mode Select Switch (MSS)
Mode Select Switch (MSS)
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
bezel. 3. With the center console cover open, remove the floor console center finish panel screws.
4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical
connector. 5. Remove the floor console center finish panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 3993
6. Disconnect the electrical connector(s). Disengage the locking tangs and remove the mode select
switch (MSS) from the instrument panel center
finish panel.
7. To install, reverse the removal procedure.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 09-1-2 >
Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC
P0456 Stored In ECM
TSB 09-1-2
01/26/09
MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC)
P0456 - BUILT ON OR BEFORE 4/14/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-16-10 to add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or
before 4/14/2008 may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code
(DTC) P0456 in the powertrain control module (PCM) memory with no other PCM trouble codes.
ACTION Follow the Service Procedure steps to reprogram the PCM and the transmission control
module (TCM) if necessary.
SERVICE PROCEDURE
Use the correct procedure for the vehicle application you are working on. For all 4.0L engines
follow Procedure A and for all 4.6L engines follow Procedure B.
Procedure A (4.0L Engine)
1. Reprogram the PCM to the latest calibration using Integrated Diagnostic System (IDS) release
52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD.
Calibration files may also be obtained at the website.
Procedure B (4.6L Engine)
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE
FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE
PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE
COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM
WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO
FOLLOW THE IDS PROMPTS
1. Install IDS / Portable Diagnostic Software (PDS) or equivalent and identify (ID) the vehicle.
2. Update the PCM and TCM calibration using IDS release 52.8 and higher or 53.1 and higher.
This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be
obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the
PCM to ensure that engine and transmission calibrations are updated to the latest level
simultaneously.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
(3) Choose Reset KAM.
(4) Then Choose TCM.
b. Using PDS:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 09-1-2 >
Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4002
(1) Choose all Tests and Calibrations.
(2) Scroll down the menu and Choose Reset TCM KAM.
NOTE
FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE
TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE.
NOTE
UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM.
NOTE
DO NOT CLEAR THE PCM KAM.
(3) Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C).
4. If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature.
NOTE
TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5.
5. Drive unit to perform adaptive shift strategy learn.
a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal.
b. Brake very gently to a complete stop (allow at least six (6) seconds).
c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting.
d. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift.
e. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds
between 1300-1800 RPM.
f. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift.
g. Brake gently to a complete stop and hold foot on brake for at least 10 seconds.
h. Repeat Steps (e-f) a total of three (3) times.
NOTE
AUTHORIZATION DECAL NOT REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions 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
090102A 2006-2008 Explorer, 0.3 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 4.0L Engine: Check DTCs, Reprogram The PCM (Do
Not Use With 12650D)
090102B 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 4.6L Engine: Check DTCs, Reprogram The PCM And
TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 09-1-2 >
Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4003
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-24-4 >
Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump
PROM - Programmable Read Only Memory: Customer Interest A/T, Engine Controls - Low Speed
Driveline Bump
TSB 08-24-4
12/08/08
DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H)
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-4-16 to update the Service Procedure.
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Explorer Sport Trac vehicles
equipped with a 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10
MPH (16 Km/h). The following procedure will improve the bump felt while braking to a stop.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR /
REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE.
1. Install Integrated Diagnostic System (IDS) / Portable Diagnostic Software (PDS) or equivalent
and ID the vehicle.
2. Update the powertrain control module (PCM) and transmission control module (TCM) calibration
using IDS release 57.11 and higher or 58.2 and higher. This new calibration is not included in the
VCM 2008.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot
be independently reprogrammed, reprogram the Programmable Module Installation (PMI) function
to ensure that engine and transmission calibrations are updated to the latest level simultaneously.
NOTE
AUTHORIZATION DECAL NOT REQUIRED.
a. Verify that the TCM Calibration shows 8L2P-7J104-AC, (8L2P-7J 104-CC for builds after
12/3/2007) part number after reprogramming is complete.
Select the following from the IDS tool, Toolbox, Powertrain, OBD Test Modes, Mode Level 9
Vehicle Info, TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
(3) Choose Reset KAM.
(4) Then Choose TCM.
b. Using PDS:
(1) Choose all Tests and Calibrations.
(2) Scroll down the menu and Choose Reset TCM KAM.
NOTE
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-24-4 >
Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4008
FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE
TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE.
NOTE
UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM
KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE
TRANSMISSION.
NOTE
DO NOT CLEAR THE PCM KAM.
4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80° C). If it is not at
175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature.
NOTE
TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5.
NOTE
PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD.
5. Drive unit to perform adaptive shift strategy learn.
a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal.
b. Brake very gently to a complete stop (allow at least six (6) seconds).
c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting.
d. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts occur at engine speeds
between 1700-2000 RPM.
e. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift.
f. Brake gently to a complete stop and hold foot on brake for at least ten (10) seconds.
g. Repeat Steps (d-f) a total of three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING MAY BE REQUIRED FOR THE TRANSMISSION TO FULLY
ADAPT.
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
082404A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 6R60 Transmission: Check DTCs, Reprogram The
PCM And TCM, Includes Time To Clear KAM And Perform Road Tests, Authorization Decal Not
Required (Do Not Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-24-4 >
Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4009
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-9-5 >
May > 08 > Engine Controls - Hard Start/Rough Idle After Hot Soak
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Hard Start/Rough
Idle After Hot Soak
TSB 08-9-5
05/12/08
4.0L/4.6L - HARD START/ROUGH RUNNING - AFTER LONG HOT SOAK / DIP IN RPM WHEN
COMING TO A STOP - BUILT ON OR BEFORE 4/212008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Sport Trac vehicles equipped
with 4.0L or 4.6L engine and built on or before 4/2/2008 may exhibit a dip in RPM below normal
idle level of 600 RPM on deceleration with no diagnostic trouble codes (DTCs) present or a hard
start / rough running condition after a long hot soak.
ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS
release 54.6 and higher or 55.1. This new calibration is not included in the VCM 2008.3 DVD.
Calibration files may also be obtained at the 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
080905A 2006-2008 0.3 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Check For DTCs And Reprogram The PCM
Authorization Decal Not Required (Do Not Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-23-2 >
Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel
PROM - Programmable Read Only Memory: Customer Interest A/T - Delayed
Engagement/Hesitation/Bump on Decel
TSB 07-23-2
11/26/07
6R60 TRANSMISSION EQUIPPED VEHICLES ONLY - BUMP WHILE BRAKING - BELOW 10
MPH (16 KM/H), DELAYED ENGAGEMENT, HESITATION ON TIP-IN AFTER BRAKING
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 07-13-8 to update the Service Procedure.
ISSUE
Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped
with 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16
Km/h). Some vehicles built prior to 05/4/2006 may exhibit the following symptoms:
^ Delayed engagements into Drive from Park Neutral or Reverse.
^ Hesitation upon tip-in after braking to a stop.
This fixes the bump while braking to a stop, improves the delayed engagements and reduces the
incidence of tip-in hesitation while accelerating from a stop.
ACTION Follow the Service Procedure steps to reprogram the transmission control module (1CM)
and the powertrain control module (PCM). Some tip-in hesitation is normal on this transmission in
order to provide smooth operation. This calibration update will help to improve the condition. The
harsh bump while braking to a stop will be eliminated. Several days of driving may be required for
the transmission to fully adapt.
SERVICE PROCEDURE
NOTE
DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC
REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE.
1. Install IDS/PDS or equivalent and ID the vehicle.
2. Update the PCM and TCM calibration using IDS release 51.8 and higher or 52.1 and higher.
Calibration files may also be obtained at the website. Since the TCM cannot be independently
reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are
updated to the latest level simultaneously.
3. Clear 1CM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
(3) Choose Reset KAM.
(4) Then Choose 1CM.
b. Using PDS:
(1) Choose all Tests and Calibrations.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-23-2 >
Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel > Page 4018
(2) Scroll down the menu and Choose Reset TCM KAM.
NOTE
FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE
TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE.
NOTE
UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM.
NOTE
DO NOT CLEAR THE PCM KAM.
4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80°C). If it is not at
175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature.
NOTE
TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5.
5. Drive unit to perform adaptive shift strategy learn.
a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds
between 1300-1800 RPM.
b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear.
c. Brake gently to a complete stop and hold foot on brake for at least 15 seconds.
d. Repeat Steps (a-c) a total of five (5) times.
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
072302A 2006-2008 Explorer, 0.9 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 4.6L 6R60 Transmission: Check DTCs, Reprogram
The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With
12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-10-12 >
May > 07 > Engine, A/T Control - Various Driveability Issues
PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Control - Various
Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 07-10-12 >
May > 07 > Engine, A/T Control - Various Driveability Issues > Page 4023
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
ON/DTC P0456 Stored In ECM
TSB 09-1-2
01/26/09
MALFUNCTION INDICATOR LAMP (MIL) ON WITH DIAGNOSTIC TROUBLE CODE (DTC)
P0456 - BUILT ON OR BEFORE 4/14/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-16-10 to add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or
before 4/14/2008 may exhibit a malfunction indicator lamp (MIL) on with diagnostic trouble code
(DTC) P0456 in the powertrain control module (PCM) memory with no other PCM trouble codes.
ACTION Follow the Service Procedure steps to reprogram the PCM and the transmission control
module (TCM) if necessary.
SERVICE PROCEDURE
Use the correct procedure for the vehicle application you are working on. For all 4.0L engines
follow Procedure A and for all 4.6L engines follow Procedure B.
Procedure A (4.0L Engine)
1. Reprogram the PCM to the latest calibration using Integrated Diagnostic System (IDS) release
52.8 and higher or 53.1 and higher. This new calibration is not included in the VCM 2007.11 DVD.
Calibration files may also be obtained at the website.
Procedure B (4.6L Engine)
NOTE
VEHICLES EQUIPPED WITH A PCM AND TCM, REQUIRE A COORDINATED
REPROGRAMMING. THIS COORDINATED REPROGRAMMING PROCEDURE MUST BE
FOLLOWED EXACTLY AS OUTLINED BY THE IDS. FAILURE TO FOLLOW THE KEY CYCLE
PROCEDURE WITHOUT WAITING FOR THE IDS PROMPTS, WILL CAUSE THE
COORDINATED REPROGRAMMING TO FAIL. THE PCM WILL BE UPDATED BUT THE 1CM
WILL NOT BE UPDATED AND THE NEW FILES WILL NOT BE INSTALLED. IT IS CRITICAL TO
FOLLOW THE IDS PROMPTS
1. Install IDS / Portable Diagnostic Software (PDS) or equivalent and identify (ID) the vehicle.
2. Update the PCM and TCM calibration using IDS release 52.8 and higher or 53.1 and higher.
This new calibration is not included in the VCM 2007.11 DVD. Calibration files may also be
obtained at the website. Since the TCM cannot be independently reprogrammed, reprogram the
PCM to ensure that engine and transmission calibrations are updated to the latest level
simultaneously.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
(3) Choose Reset KAM.
(4) Then Choose TCM.
b. Using PDS:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4029
(1) Choose all Tests and Calibrations.
(2) Scroll down the menu and Choose Reset TCM KAM.
NOTE
FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE
TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE.
NOTE
UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM.
NOTE
DO NOT CLEAR THE PCM KAM.
(3) Verify that the transmission fluid temperature (TFT) PID is above 175 °F (80 °C).
4. If it is not at 175 °F (80 °C), drive unit approximately 3 miles (5 Km) to reach temperature.
NOTE
TFT MUST BE AT 175 °F (80 °C) OR ABOVE BEFORE PROCEEDING TO STEP 5.
5. Drive unit to perform adaptive shift strategy learn.
a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal.
b. Brake very gently to a complete stop (allow at least six (6) seconds).
c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting.
d. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift.
e. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds
between 1300-1800 RPM.
f. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift.
g. Brake gently to a complete stop and hold foot on brake for at least 10 seconds.
h. Repeat Steps (e-f) a total of three (3) times.
NOTE
AUTHORIZATION DECAL NOT REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions 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
090102A 2006-2008 Explorer, 0.3 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 4.0L Engine: Check DTCs, Reprogram The PCM (Do
Not Use With 12650D)
090102B 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 4.6L Engine: Check DTCs, Reprogram The PCM And
TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With 12650D)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
09-1-2 > Jan > 09 > Engine Controls - MIL ON/DTC P0456 Stored In ECM > Page 4030
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECALEM 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T, Engine Controls Low Speed Driveline Bump
TSB 08-24-4
12/08/08
DRIVELINE BUMP WHILE BRAKING - BELOW 10 MPH (16 KM/H)
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-4-16 to update the Service Procedure.
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Explorer Sport Trac vehicles
equipped with a 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10
MPH (16 Km/h). The following procedure will improve the bump felt while braking to a stop.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC REPAIR /
REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE.
1. Install Integrated Diagnostic System (IDS) / Portable Diagnostic Software (PDS) or equivalent
and ID the vehicle.
2. Update the powertrain control module (PCM) and transmission control module (TCM) calibration
using IDS release 57.11 and higher or 58.2 and higher. This new calibration is not included in the
VCM 2008.11 DVD. Calibration files may also be obtained at the website. Since the TCM cannot
be independently reprogrammed, reprogram the Programmable Module Installation (PMI) function
to ensure that engine and transmission calibrations are updated to the latest level simultaneously.
NOTE
AUTHORIZATION DECAL NOT REQUIRED.
a. Verify that the TCM Calibration shows 8L2P-7J104-AC, (8L2P-7J 104-CC for builds after
12/3/2007) part number after reprogramming is complete.
Select the following from the IDS tool, Toolbox, Powertrain, OBD Test Modes, Mode Level 9
Vehicle Info, TCM Cal Part Number.
3. Clear TCM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
(3) Choose Reset KAM.
(4) Then Choose TCM.
b. Using PDS:
(1) Choose all Tests and Calibrations.
(2) Scroll down the menu and Choose Reset TCM KAM.
NOTE
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4035
FOR PDS, RESET TCM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE
TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE.
NOTE
UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM. IT IS CRITICAL THAT TCM
KAM BE CLEARED PRIOR TO RELEARNING THE ADAPTIVE TABLES FOR THE
TRANSMISSION.
NOTE
DO NOT CLEAR THE PCM KAM.
4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80° C). If it is not at
175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature.
NOTE
TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5.
NOTE
PERFORM ADAPTIVE SHIFT STRATEGY LEARN ON LEVEL SURFACE ROAD.
5. Drive unit to perform adaptive shift strategy learn.
a. Accelerate from rest with light throttle to 15 MPH (24 Km/h), remove foot from accelerator pedal.
b. Brake very gently to a complete stop (allow at least six (6) seconds).
c. Repeat steps (a-b) five (5) times in the dealership parking lot or similar setting.
d. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts occur at engine speeds
between 1700-2000 RPM.
e. Continue to accelerate gently to 50 MPH (80 Km/h) or the 5-6 upshift.
f. Brake gently to a complete stop and hold foot on brake for at least ten (10) seconds.
g. Repeat Steps (d-f) a total of three (3) times.
NOTE
THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER,
SEVERAL DAYS OF DRIVING MAY BE REQUIRED FOR THE TRANSMISSION TO FULLY
ADAPT.
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
082404A 2006-2008 Explorer, 1.0 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 6R60 Transmission: Check DTCs, Reprogram The
PCM And TCM, Includes Time To Clear KAM And Perform Road Tests, Authorization Decal Not
Required (Do Not Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
08-24-4 > Dec > 08 > A/T, Engine Controls - Low Speed Driveline Bump > Page 4036
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
08-9-5 > May > 08 > Engine Controls - Hard Start/Rough Idle After Hot Soak
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Hard
Start/Rough Idle After Hot Soak
TSB 08-9-5
05/12/08
4.0L/4.6L - HARD START/ROUGH RUNNING - AFTER LONG HOT SOAK / DIP IN RPM WHEN
COMING TO A STOP - BUILT ON OR BEFORE 4/212008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Sport Trac vehicles equipped
with 4.0L or 4.6L engine and built on or before 4/2/2008 may exhibit a dip in RPM below normal
idle level of 600 RPM on deceleration with no diagnostic trouble codes (DTCs) present or a hard
start / rough running condition after a long hot soak.
ACTION Reprogram the powertrain control module (PCM) to the latest calibration using IDS
release 54.6 and higher or 55.1. This new calibration is not included in the VCM 2008.3 DVD.
Calibration files may also be obtained at the 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
080905A 2006-2008 0.3 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Check For DTCs And Reprogram The PCM
Authorization Decal Not Required (Do Not Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - Delayed
Engagement/Hesitation/Bump on Decel
TSB 07-23-2
11/26/07
6R60 TRANSMISSION EQUIPPED VEHICLES ONLY - BUMP WHILE BRAKING - BELOW 10
MPH (16 KM/H), DELAYED ENGAGEMENT, HESITATION ON TIP-IN AFTER BRAKING
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 07-13-8 to update the Service Procedure.
ISSUE
Some 2006-2008 Explorer 4dr, Mountaineer and 2007-2008 Explorer Sport Trac vehicles equipped
with 6R60 transmission may exhibit a bump feeling while braking to a stop less than 10 MPH (16
Km/h). Some vehicles built prior to 05/4/2006 may exhibit the following symptoms:
^ Delayed engagements into Drive from Park Neutral or Reverse.
^ Hesitation upon tip-in after braking to a stop.
This fixes the bump while braking to a stop, improves the delayed engagements and reduces the
incidence of tip-in hesitation while accelerating from a stop.
ACTION Follow the Service Procedure steps to reprogram the transmission control module (1CM)
and the powertrain control module (PCM). Some tip-in hesitation is normal on this transmission in
order to provide smooth operation. This calibration update will help to improve the condition. The
harsh bump while braking to a stop will be eliminated. Several days of driving may be required for
the transmission to fully adapt.
SERVICE PROCEDURE
NOTE
DO NOT ATTEMPT TO REPLACE THE MECHATRONIC UNIT. MECHATRONIC
REPAIR/REPLACEMENT IS NOT AUTHORIZED FOR THIS ISSUE.
1. Install IDS/PDS or equivalent and ID the vehicle.
2. Update the PCM and TCM calibration using IDS release 51.8 and higher or 52.1 and higher.
Calibration files may also be obtained at the website. Since the TCM cannot be independently
reprogrammed, reprogram the PCM to ensure that engine and transmission calibrations are
updated to the latest level simultaneously.
3. Clear 1CM keep alive memory (KAM) and adaptive tables.
a. Using IDS:
(1) Open Toolbox.
(2) Choose Powertrain.
(3) Choose Reset KAM.
(4) Then Choose 1CM.
b. Using PDS:
(1) Choose all Tests and Calibrations.
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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: >
07-23-2 > Nov > 07 > A/T - Delayed Engagement/Hesitation/Bump on Decel > Page 4045
(2) Scroll down the menu and Choose Reset TCM KAM.
NOTE
FOR PDS, RESET 1CM KAM IS NOT THE SAME AS CLEAR TRANSMISSION ADAPTIVE
TABLES, WHICH IS UNDER THE POWERTRAIN - TRANSMISSION MENU TREE.
NOTE
UNHOOKING THE BATTERY WILL NOT CLEAR THE TCM KAM.
NOTE
DO NOT CLEAR THE PCM KAM.
4. Verify that the transmission fluid temperature (TFT) PID is above 175° F (80°C). If it is not at
175° F (80° C), drive unit approximately 3 miles (5 Km) to reach temperature.
NOTE
TFT MUST BE AT 175° F (80° C) OR ABOVE BEFORE PROCEEDING TO STEP 5.
5. Drive unit to perform adaptive shift strategy learn.
a. Accelerate from rest with light throttle. The 1-2, 2-3, and 3-4 shifts must occur at engine speeds
between 1300-1800 RPM.
b. Continue to accelerate gently to 50 MPH (80 Km/h) so that the transmission shifts into 6th gear.
c. Brake gently to a complete stop and hold foot on brake for at least 15 seconds.
d. Repeat Steps (a-c) a total of five (5) times.
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
072302A 2006-2008 Explorer, 0.9 Hr.
Mountaineer 2007-2008 Explorer Sport Trac 4.6L 6R60 Transmission: Check DTCs, Reprogram
The PCM And TCM, Includes Time To Clear KAM And Perform Road Tests (Do Not Use With
12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
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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: >
07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Control Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: >
07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page 4050
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4058
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4059
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4060
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4061
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4062
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4063
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4064
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4065
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4066
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4067
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 4068
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 4069
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4070
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4071
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4073
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4074
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Brake Shift Interlock Actuator
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
brake shift lock actuator electrical connector.
3. Remove the screw and the brake shift lock actuator.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4078
Installation
1. Install the brake shift lock actuator.
2. Connect the brake shift lock actuator electrical connector.
3. Install the front floor console. For additional information, refer to Console.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Shift Solenoid: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4083
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4084
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4085
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4086
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4087
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4088
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4089
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4090
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4091
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4092
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4093
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4094
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4095
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4096
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4097
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4098
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4099
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4104
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4105
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4106
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4107
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4108
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4109
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4110
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4111
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4112
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4113
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4114
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4115
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4116
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4117
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4118
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4119
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4120
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair
Transfer Case Actuator: Service and Repair
Transfer Case Shift Motor
Material
Removal and Installation
1. With the ignition ON, press the 4x4 HIGH button on the mode select switch (MSS). 2. With the
transmission in the NEUTRAL position, raise and support the vehicle. For additional information,
refer to Maintenance/Service and
Repair.
3. Disconnect the transfer case shift motor harness connector.
4. Remove the bracket bolt and transfer case shift motor mounting bolts and remove the transfer
case shift motor.
5. To install, reverse the removal procedure.
^ Apply a coat of Multi-Purpose Grease to the transfer case shift motor bolts.
^ Tighten to 10 Nm (89 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4131
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4132
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4133
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4134
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4135
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4136
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4137
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4138
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4139
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4140
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4141
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4142
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4143
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4144
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4145
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4146
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4147
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Brake Shift Interlock Actuator
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
brake shift lock actuator electrical connector.
3. Remove the screw and the brake shift lock actuator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4151
Installation
1. Install the brake shift lock actuator.
2. Connect the brake shift lock actuator electrical connector.
3. Install the front floor console. For additional information, refer to Console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4156
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4157
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4158
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4159
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4160
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4161
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4162
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4163
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4164
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4165
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4166
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4167
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4168
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4169
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4170
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4171
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4172
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 4177
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4178
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4179
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4180
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4181
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4182
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4183
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4184
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4185
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4186
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4187
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4188
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4189
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4190
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4191
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4192
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4193
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
Band Apply Servo: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4202
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4203
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4204
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 09-12-12 > Jun > 09 >
A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4205
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
Band Apply Servo: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4211
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4212
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4213
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 09-12-12 >
Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 4214
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions
Brake Switch - TCC: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4219
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4220
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4221
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4222
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4223
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4224
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4225
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4226
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4227
Brake Switch - TCC: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4228
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4229
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4230
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4231
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4232
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4233
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4234
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Diagram Information and Instructions > Page 4235
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
Component Information > Diagrams > Page 4236
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set
Case: Customer Interest A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 4245
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 4246
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 4247
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th
Gears/Ratio DTC's Set > Page 4248
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set
Case: All Technical Service Bulletins A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set
TSB 09-12-12
06/29/09
5R555/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH
GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN
BORE WEAR
FORD: 2002-2005 Thunderbird 2005-2009 Mustang 2002-2009 Explorer 2007-2009 Explorer Sport
Trac
LINCOLN: 2002-2006 Lincoln LS 2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer
ISSUE Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006
Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped
with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd,
3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case
bore wear causing reduced apply pressure.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
For transmissions that have been determined to require an overhaul or rebuild and the overdrive
band or intermediate band have excessive wear or burned/damaged band friction material, the
cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles,
usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes
worse when hot. (Figure 1)
In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore
located closest to the bell housing. When we refer to the intermediate bore, we are talking about
the larger bore located next to the line pressure tap.
Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool
5RW Master Kit part number NRL5RW servo pin bore repair system (1-800-768-8632 option 6).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 4254
1. Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the
case with the servo's snap-ring. (Figure 2)
2. Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use,
as long as one of the lands is under the 3/8" Allen
screw.
NOTE
CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES,
PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.
3. Ream out the bore using the 9/16" reamer applying ample lubrication.
NOTE
DO NOT REAM ABOVE 500 RPM. (Figure 3)
4. Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
5. Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too
hard on the reamer or turn the reamer faster than
500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 4255
a. The shorter bushing is for the intermediate servo and is identified by a flat ground in the
bushing's hat. (Figure 4A)
b. Overdrive servo bushing. (Figure 4B)
c. Both bushings are chamfered and need to be installed with the recessed edge up (away from the
valve body).
7. Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive
the bushing in by hitting the driver until the bushing
bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut
in the handle.
8. After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following
the servo apply holes in the case 5R555 case
shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 4256
a. Overdrive servo. (Figure 6)
b. Intermediate servo. (Figure 7)
NOTE
FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO
SHIFT CONDITION.
9. Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing
with a rubber mallet. Once the pin is inside the bushing,
use a punch to drive the pin all the way through the bushing. Repeat as necessary. (Figure 8)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 09-12-12 > Jun > 09 > A/T - Loss Of
2nd/3rd/5th Gears/Ratio DTC's Set > Page 4257
Correctly installed bushings will be flush inside of case. (Figure 9)
The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the
cutting edges to help provide optimum bushing installation and increased tool life.
After bushing installation, thoroughly wash the case before rebuilding transmission.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications
Clutch: Specifications
Clutch Application Chart
Clutch Application Chart (Part 1)
Clutch Application Chart (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Page 4261
Clutch Application Chart (Part 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-10-12 > May > 07 >
Engine, A/T Control - Various Driveability Issues
Control Module: Customer Interest Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-10-12 > May > 07 >
Engine, A/T Control - Various Driveability Issues > Page 4270
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4275
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4276
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4277
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-10-12 >
May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: All Technical Service Bulletins Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-10-12 >
May > 07 > Engine, A/T Control - Various Driveability Issues > Page 4283
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr >
07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr >
07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4288
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr >
07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4289
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr >
07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4290
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid 5R55S ..................................................................................................................
............................................................................. 12.4 quarts (11.7 liters) 6R60 ................................
..............................................................................................................................................................
.... 11.2 quarts (10.6 liters)
Note: Indicates only approximate dry-fill capacity. Some applications may vary based on cooler
size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should
be checked by a qualified technician.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 4295
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
5R55S ..................................................................................................................................................
............................................. MERCON V XT-5-QM 6R60 ..................................................................
............................................................................................................................. MERCON SP
XT-6-QSP
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill
Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill
Transmission Fluid Drain and Refill
Special Tool(s)
Material
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. NOTE: Some fluid leakage may occur when removing the fluid fill plug.
Remove the fluid fill plug fluid level indicator assembly located on the passenger side front portion
of the transmission case. Removal of the plug will relieve any vacuum that might have built up in
the transmission. This will aid in allowing the fluid pan to be easily removed when the bolts are
removed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4298
3. Remove the transmission fluid pan and allow the fluid to drain.
4. Install the transmission fluid pan.
^ Tighten to 14 Nm (10 ft. lbs.)
Transmission Fluid Refill
CAUTION: This procedure contains the air purge steps required to purge air from the cooling
system. This procedure is NOT intended for use with the Transmission Fluid Level Check.
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result.
CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot
during this procedure.
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level
should be checked.
NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure.
^ Adding 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission is an initial fill
enabling you to start the engine.
^ The cold level range shown in the procedure allows the vehicle to be driven.
^ The vehicle should be driven to allow the transmission fluid temperature to reach 85°C - 88°C
(185°F - 190°F) in order to purge the air from the transmission cooling system.
^ Fill the transmission fluid to the fill range on the fluid level indicator at the normal operating range
80°C - 85°C (175°F - 185°F).
1. NOTE: The transmission will need 3.3L (3.5 qt) of clean automatic transmission fluid added to
the transmission as an initial fill if:
^ the transmission has been overhauled.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4299
^ a new Mechatronic assembly has been installed.
^ the transmission fluid pan or fluid filter have been removed.
Using the special tool, add 3.3L (3.5 qt) of clean automatic transmission fluid to the transmission
through the fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in
this procedure.
2. Check the transmission fluid level cold.
1 The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C - 43°C (90°F 110°F).
^ Using the scan tool and the engine running, place the transmission selector lever in each gear
position and hold approximately 5 seconds. Place the transmission selector lever in PARK, with the
engine at idle (600 - 750 rpm).
3. Separate the fluid level indicator from the fill plug.
4. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug
hole to check the fluid level. Repeat this until a
consistent reading is established.
5. Add clean transmission fluid to the cold level location as shown in the illustration.
6. Install the fluid fill plug.
^ Tighten to 35 Nm (26 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4300
7. While driving the vehicle, use the scan tool to verify that the transmission fluid temperature has
reached a temperature of 88°C (190°F). This will
circulate the transmission fluid through the torque converter and the cooling system, eliminating
any trapped air in the cooling system. ^
With the engine idling (600 - 750 rpm) in PARK, verify that the transmission fluid temperature is
between 80°C - 85°C (175°F - 185°F).
8. Remove the fluid fill plug fluid level indicator assembly located on the passenger side front
portion of the transmission case.
9. Separate the fluid level indicator from the fill plug.
10. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug
hole to check the fluid level. Repeat this until a
consistent reading is established.
11. Using the scan tool verify that the transmission fluid temperature is between 80°C - 85°C
(175°F - 185°F). The fluid level must be at the upper
level of the crosshatch mark.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4301
12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid in this procedure.
Install the fluid fill plug. ^
Tighten to 35 Nm (26 ft. lbs.)
Adding Additional Transmission Fluid
NOTE: To get an accurate fluid level reading the engine should be idling (600 - 750 rpm) in PARK.
1. Install the special tool into the fluid fill hole.
2. Fill the special tool with approximately 0.47L (1 pt) of clean automatic transmission fluid.
3. Hang the special tool under the vehicle, upright and close to the transmission.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4302
4. Connect the special tools.
^ Connect the open end of the fluid hose from the special tool onto the special tool from the
transmission case.
5. 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.
6. NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the
crosshatch mark.
Reinstall the fluid level indicator only back into the fill plug hole to check the fluid level. Repeat this
until a consistent reading is established.
7. Using the scan tool verify that the transmission fluid temperature is between 80°C - 85°C (175°F
- 185°F). The fluid level must be at the upper
level of the crosshatch mark.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4303
8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in
this procedure.
Install the fluid fill plug. ^
Tighten to 35 Nm (26 ft. lbs.)
Removing Transmission Fluid
NOTE: To get an accurate fluid level reading the engine should be idling (600 - 750 rpm) in PARK.
1. If the transmission is overfilled, fluid must be removed to the correct level. Use the special tools
to extract any excessive fluid.
2. Using the scan tool, verify that the transmission fluid temperature is between 80°C - 85°C (175°F
- 185°F). The fluid level must be at the upper
level of the crosshatch mark. Reinstall the fluid level indicator only back into the fill plug hole to
check the fluid level. Repeat this until a consistent reading is established.
3. Install the fluid fill plug.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4304
^ Tighten to 35 Nm (26 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4305
Fluid - A/T: Service and Repair Transmission Fluid Level Check
Transmission Fluid Level Check
Special Tool(s)
Material
CAUTION: The vehicle should not be driven if the fluid level is low as internal failure could result.
CAUTION: The fluid fill plug is located near the exhaust system. The exhaust will be extremely hot
during this procedure.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city
traffic, during hot weather or while pulling a trailer, the fluid must cool down to obtain an accurate
reading.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of fluid leaking, the fluid level
should be checked.
NOTE: Do not overfill the transmission. The fluid level must be at the upper level of the crosshatch
mark.
NOTE: If the installation of a new transmission fluid cooler, cooler lines have been carried out the
vehicle must be driven to get the transmission fluid to a temperature of 88°C (190°F) in order to
purge the air from the cooling system.
1. With the engine running, place the transmission selector lever in each gear position and hold
approximately 5 seconds. Place the transmission
selector lever in PARK.
2. With the engine idling (600 - 750 rpm) in PARK, position it on a hoist. For additional information,
refer to Maintenance/Service and Repair. 3. Remove the fluid fill plug fluid level indicator assembly,
located on the passenger side front portion of the transmission case.
4. Separate the fluid level indicator from the fill plug.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4306
5. Wipe the fluid level indicator clean. Reinstall the fluid level indicator only back into the fill plug
hole to check the fluid level.
6. Using the scan tool, verify that the transmission fluid temperature is between 80°C - 85°C (175°F
- 185°F). Do not overfill the transmission. The
fluid level must be at the upper level of the crosshatch mark.
7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission
Fluid.
Install the fluid fill plug. ^
Tighten to 35 Nm (26 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Transmission Fluid Drain and Refill > Page 4307
Fluid - A/T: Service and Repair Transmission Fluid Cooler - Backflushing and Cleaning
Transmission Fluid Cooler - Backflushing and Cleaning
Material
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the cooler lines and install a new cooler before placing the transmission in use.
CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the
cooling system or transmission could occur.
1. Install a new transmission fluid cooler if any fluid leaks are indicated or a major metallic failure is
indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines.
3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting
them to the cleaner.
Connect the cleaner pressure and return lines appropriately. 1
Connect the pressure line to the fluid cooler inlet tube.
2 Connect the return line to the fluid cooler outlet tube.
3 Place the outlet end of the return line in the fluid tank reservoir.
4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system.
Switch the fluid pumps ON. Allow the fluid to circulate a minimum of 5 minutes.
5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7.
Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove
the rubber hoses from the fluid cooler tubes.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair
Fluid Filter - A/T: Service and Repair
Fluid Pan, Gasket and Filter
Material
Removal
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the fill plug fluid level indicator assembly located on
the passenger side front portion of the transmission case. Removal of the plug will
relieve any vacuum that might have built up in the transmission. This will allow the fluid pan to be
easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the fluid to drain.
4. Remove the fluid pan gasket.
5. Remove and discard the transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 4311
6. Clean and inspect the transmission fluid pan and magnet.
Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new
transmission fluid filter and seal assembly. The fluid filter may be reused if no excessive
contamination is indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case,
carefully remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with clean
automatic transmission fluid.
3. NOTE: The fluid filter may be reused if no excessive contamination is indicated.
Install a new transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Page 4312
4. Position the magnet in the transmission fluid pan.
5. NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
6. Install the fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 ft. lbs.)
7. Using the refill procedure, fill the transmission with clean automatic transmission fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Tubes
Transmission Fluid Cooler Tubes - 6R60
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4317
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the secondary latch from the cooler tube.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4318
3. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid
cooler tube from the radiator.
4. Remove the secondary latch from the cooler tube.
5. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid
cooler tube from the transmission fluid cooler
hose.
6. Remove the transmission fluid cooler tube bracket nut.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4319
7. If equipped, index-mark the front driveshaft to maintain driveshaft balance.
8. If equipped, remove the 4 universal joint strap bolts and remove the universal joint straps.
^ Discard the bolts.
9. Disconnect the engine oil level sensor electrical connector.
10. NOTE: The cooler tube O-rings may remain in the transmission case. Carefully remove them
from the case.
Remove the bolt and disconnect the transmission fluid cooler tubes from the transmission.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4320
11. Remove and discard the 4 O-rings from the tube ends.
12. Remove the transmission fluid cooler tubes from the vehicle.
Installation
1. Position the transmission fluid cooler tubes in the vehicle.
2. Install 4 new O-rings on the transmission fluid cooler tube ends.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4321
3. NOTE: Inspect the transmission case to make sure that the old O-rings are not stuck in the
transmission case.
Position the transmission fluid cooler tubes into the transmission, then install the bolt for the
transmission cooler tube retainer. ^
Tighten to 25 Nm (18 ft. lbs.)
4. Install the transmission fluid cooler tube bracket and install the transmission fluid cooler tube
bracket nut.
^ Tighten to 12 Nm (9 ft. lbs.)
5. NOTE: Install new universal joint strap bolts. If new universal joint strap bolts are not available,
coat the threads of the original universal joint
strap bolts with Threadlock and sealer.
If removed, install the universal joint straps and 4 new universal joint strap bolts. ^
Tighten to 19 Nm (14 ft. lbs.)
6. Connect the engine oil level sensor electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4322
7. Connect the transmission fluid cooler tube to the radiator.
8. Install the secondary latch to the transmission fluid cooler tube at the radiator.
9. Connect the transmission fluid cooler tube to the transmission fluid cooler hose.
10. Install the secondary latch to the transmission fluid cooler tube at the cooler hose.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4323
11. Fill the transmission fluid to the correct level, using clean automatic transmission fluid, and
inspect for leaks.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4324
Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hoses
Transmission Fluid Cooler Hoses
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4325
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
Mountaineer
2. Remove the grille fasteners and the grille.
Explorer
3. Remove the bumper cover.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4326
4. Remove the inner grille air deflector.
5. Push the lower air deflector down past the transmission fluid cooler.
6. Disconnect the transmission fluid cooler hoses.
^ Remove and discard the transmission fluid cooler hoses and the clamps.
7. Remove the secondary latch from the transmission fluid cooler tube.
8. Using the special tool, disconnect the quick connect coupler and separate the transmission fluid
cooler tube from the transmission cooler hose.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4327
9. Remove the secondary latch from the transmission fluid cooler hose.
10. Using the special tool, disconnect the quick connect coupler and remove the transmission fluid
cooler tube from the radiator.
11. Remove the hoses from the retainer. Installation
All vehicles
1. Install the hoses into the retainer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4328
2. Install the transmission fluid cooler hose to the radiator.
3. Install the secondary latch.
4. Install the transmission fluid cooler hose to the transmission fluid cooler tube.
5. Install the secondary latch.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4329
6. NOTE: Clean the cooler tube stems with degreaser prior to installing the hoses.
Using new hoses and clamps, install the new transmission fluid cooler hoses.
7. Push the lower air deflector back into place.
8. Install the inner grille air deflector.
Mountaineer
9. Install the grille and the fasteners.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Service and Repair > Transmission Fluid Cooler Tubes > Page 4330
Explorer
10. Install the bumper cover.
All vehicles
11. Fill the transmission fluid to the correct level using clean automatic transmission fluid and
inspect for leaks.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications
Fluid Pan: Specifications
Transmission fluid pan bolts
.................................................................................................................................. 14 Nm (10 ft.
lbs.) in a crisscross pattern
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 4334
Fluid Pan: Service and Repair
Fluid Pan, Gasket and Filter
Material
Removal
CAUTION: The use of any other transmission fluid than specified, can result in the transmission
failing to operate in a normal manner or transmission failure.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the fill plug fluid level indicator assembly located on
the passenger side front portion of the transmission case. Removal of the plug will
relieve any vacuum that might have built up in the transmission. This will allow the fluid pan to be
easily removed when the bolts are removed.
3. Remove the transmission fluid pan and allow the fluid to drain.
4. Remove the fluid pan gasket.
5. Remove and discard the transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 4335
6. Clean and inspect the transmission fluid pan and magnet.
Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new
transmission fluid filter and seal assembly. The fluid filter may be reused if no excessive
contamination is indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case,
carefully remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with clean
automatic transmission fluid.
3. NOTE: The fluid filter may be reused if no excessive contamination is indicated.
Install a new transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Specifications > Page 4336
4. Position the magnet in the transmission fluid pan.
5. NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
6. Install the fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 ft. lbs.)
7. Using the refill procedure, fill the transmission with clean automatic transmission fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Transmission Mode Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Overdrive Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4345
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4346
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4347
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4348
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4349
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4350
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4351
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4352
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4353
Overdrive Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4354
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4355
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4356
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4357
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4358
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4359
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4360
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4361
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4366
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4367
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4368
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4369
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4370
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4371
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4372
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4373
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4374
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4375
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4376
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4377
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4378
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4379
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4380
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4381
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4382
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: Customer Interest Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page 4392
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4397
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4398
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4399
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: All Technical Service Bulletins Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page 4405
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4410
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4411
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4412
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal
Seals and Gaskets: Service and Repair Output Shaft Seal
Output Shaft Seal
Special Tool(s) (Part 1)
Special Tool(s) (Part 2)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4417
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
Rear wheel drive (RWD) vehicles
2. Remove the rear driveshaft.
3. NOTE: The output shaft flange nut has been staked to prevent it from coming loose. Prior to
removing the nut, remove the stake to prevent
damage to the output shaft.
Remove and discard the output shaft flange nut.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4418
4. Remove the output shaft flange.
5. Using the special tools, remove the output shaft seal.
Four wheel drive (4WD) vehicles
6. Remove the transfer case. 7. Using the special tools, remove the output shaft seal.
RWD vehicles
1. Position a new output shaft seal.
2. Using the special tool, install the output shaft seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4419
3. Install the output shaft flange.
4. Install a new output shaft flange nut.
^ Tighten to 60 Nm (44 ft. lbs.)
^ After installing the new nut, it must be staked at the slots to prevent it from coming loose.
5. Install the rear driveshaft.
4WD vehicles
6. Position the output shaft seal.
7. Using the special tool, install a new output shaft seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4420
8. Install the transfer case.
All vehicles
9. Fill and check the transmission fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4421
Seals and Gaskets: Service and Repair Manual Control Lever Shaft and Seal
Manual Control Lever Shaft and Seal
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Disconnect the selector lever cable end.
3. Remove the fill plug fluid level indicator assembly located on the passenger side front portion of
the transmission case. Removal of the plug will
relieve any vacuum that might have built up in the transmission. This will allow the fluid pan to be
easily removed when the bolts are removed.
4. Remove the transmission fluid pan and allow the fluid to drain.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4422
5. Remove and discard the transmission fluid filter.
6. Remove the fluid pan gasket.
7. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on
the connector.
8. Pull the release tab and pull down on the bulkhead connector retainer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4423
9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM).
Electrostatic discharge may occur and may cause damage to the Mechatronic unit.
With the release tab down, pull the outer shell of the bulkhead electrical connector out of the
transmission control module (TCM).
10. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM.
Electrostatic discharge may occur and
may cause damage to the Mechatronic unit.
Pull the bulkhead electrical connector out of the transmission.
11. NOTE: During removal of the Mechatronic, the thermal bypass valve, pump adapter seal and
one or more center support seals may become
dislodged. Save these components for re-use during assembly.
Remove the 11 bolts from the Mechatronic assembly and remove the Mechatronic assembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4424
12. Remove the park pawl abutment.
13. Remove the manual control lever.
1 Remove the roll pin.
2 Slide the manual control lever shaft out of the case.
3 Hold the spacer to keep it from falling out of the case.
4 Remove the manual valve inner lever and the park rod as an assembly.
14. Remove and discard the manual control lever seal.
Installation
1. Position a new manual control lever seal in place.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4425
2. Using the special tool, install a new manual control lever shaft seal.
3. Install the manual lever in the case.
1 Slide the manual lever in the case.
2 Position the spacer in place while sliding the manual lever into the spacer.
3 Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole.
4 Install the roll pin.
4. Position the park rod in place. Push down on the park pawl and position the park rod in place. 5.
While holding the park rod down, install the park pawl abutment.
^ Tighten to 10 Nm (89 inch lbs.)
6. NOTE: Before installing the Mechatronic assembly into the transmission case, verify presence
and correct orientation of the thermal bypass
valve, pump adapter seal and center support seals. Also note that one or more of the center
support seals may have remained in the Mechatronic assembly during removal and should be
installed into the transmission case at this time.
Verify the 4 rubber feed tubes for the center support are in place. 1
Black feed tube.
2 Green feed tube.
3 Blue feed tube.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4426
7. Verify the rubber adapter is in place.
8. Verify the thermal bypass valve is in the case.
9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM.
Electrostatic discharge may occur and
may cause damage to the Mechatronic unit.
Position the Mechatronic assembly in place and loosely install the 11 bolts. 1
Align the manual valve and control lever linkage.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4427
10. Tighten the Mechatronic bolts in the sequence shown.
^ Tighten to 6 Nm (53 inch lbs.)
11. CAUTION: Do not touch the electrical connector pins. Electrostatic discharge may occur and
will cause damage to the Mechatronic unit.
With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector
into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
12. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place.
13. Install a new transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4428
14. NOTE: The fluid pan gasket can be reused if not damaged.
Install the transmission fluid pan gasket if necessary.
15. Install the fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 ft. lbs.)
16. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
17. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the cable end is
snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable
to click into place. Pull back on the selector lever cable to make sure that it is locked into the
bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud.
Pull back on the selector lever cable to make sure that the cable end is correctly installed.
Connect the selector lever cable onto the ball stud and move the locking tab down.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Output Shaft Seal > Page 4429
^ Listen for the audible click.
^ Pull back on the selector lever cable to make sure that it is correctly installed.
18. Using the refill procedure, fill and check the transmission fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions
Brake Switch - TCC: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4435
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4436
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4437
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4438
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4439
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4440
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4441
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4442
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4443
Brake Switch - TCC: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4444
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4445
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4446
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4447
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4448
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4449
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4450
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Diagram Information and Instructions > Page 4451
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Diagrams > Page 4452
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Overdrive Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4457
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4458
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4459
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4460
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4461
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4462
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4463
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4464
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4465
Overdrive Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4466
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4467
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4468
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4469
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4470
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4471
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4472
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4473
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor/Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4478
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4479
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4480
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4481
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4482
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4483
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4484
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4485
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4486
Throttle Position Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4487
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4488
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4489
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4490
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4491
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4492
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4493
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Throttle Position Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4494
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Mode Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4499
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4500
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4501
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4502
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4503
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4504
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4505
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4506
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4507
Transmission Mode Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4508
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4509
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4510
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4511
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4512
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4513
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4514
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4515
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC)
Switch
Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch
Transmission Control (TC) Switch
The transmission control (TC) switch is a momentary contact switch located on the selector lever
knob. Pushing the TC switch will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the
instrument panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Description and Operation > Transmission Control (TC)
Switch > Page 4518
Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS)
TRANSMISSION CONTROL SWITCH (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4519
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Removal
1. Remove the transmission selector lever knob.
2. Remove the transmission control switch from the knob.
Installation
1. Install the transmission control switch into the knob.
2. Install the transmission selector lever knob.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4524
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4525
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4526
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4527
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4528
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4529
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4530
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4531
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4532
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4533
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4534
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4535
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4536
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4537
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4538
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4539
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4540
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 4541
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4546
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4547
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4548
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4549
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4550
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4551
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4552
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4553
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4554
Transmission Speed Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4555
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4556
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4557
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4558
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4559
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4560
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4561
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4562
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4563
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
4564
C164
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4569
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4570
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4571
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4572
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4573
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4574
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4575
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4576
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4577
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4578
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4579
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4580
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4581
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4582
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4583
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4584
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4585
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Service and Repair
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Brake Shift Interlock Actuator
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
brake shift lock actuator electrical connector.
3. Remove the screw and the brake shift lock actuator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Service and Repair > Page 4590
Installation
1. Install the brake shift lock actuator.
2. Connect the brake shift lock actuator electrical connector.
3. Install the front floor console. For additional information, refer to Console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4595
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4596
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4597
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4598
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4599
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4600
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4601
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4602
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4603
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4604
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4605
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4606
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4607
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4608
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4609
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4610
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 4611
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement > Page 4620
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement > Page 4621
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement > Page 4622
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement > Page 4623
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement > Page 4624
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement > Page 4625
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Recalls: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit Board
Replacement > Page 4626
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 07-12-9 > Jun > 07 > A/T - Manual Override Required to
Shift From PARK
Shifter A/T: Customer Interest A/T - Manual Override Required to Shift From PARK
TSB 07-12-9
06/25/07
INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE
OUT OF PARK - VEHICLES BUILT ON OR BEFORE 11/14/2006
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer, Mountaineer
This article supersedes TSB 07-11-12 to update the production fix date.
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on
or before 11/14/2006 may exhibit an intermittent condition where the shifter may require the use of
the manual override function to get the shifter out of park. This condition may be caused by
chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR
BEFORE 11/14/2006. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 11/14/2006.
SERVICE PROCEDURE
1. Check the electrical system and make sure the shifter is getting power from the BOO switch
(actuate brake to confirm switch signal is getting to the shifter assembly).
2. Confirm the wiring in the shifter is okay (connections are made, no cut wires).
3. If there are no issues with wiring or other electrical components, follow Workshop Manual,
Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever
Cable Adjustment procedures to replace the Transmission Selector.
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
071209A 2006-2007 1.0 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The
Transmission Selector Lever Includes
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 07-12-9 > Jun > 07 > A/T - Manual Override Required to
Shift From PARK > Page 4632
Time For Cable Adjustment (Do Not Use With 7210A)
MT071209 Claim Additional Diagnosis Actual
Or Labor Performed As Time
Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
7210 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 07-3-8 > Feb > 07 > A/T - Manual Override Required To
Get Out of 'PARK'
Shifter A/T: Customer Interest A/T - Manual Override Required To Get Out of 'PARK'
TSB 07-3-8
02/19/07
INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE
OUT OF PARK
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer, Mountaineer
This article supersedes TSB 06-25-10 to update the vehicle model years.
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on
or before 1/23/2007 may exhibit an intermittent condition where the shifter may require the use of
the manual override function to get the shifter out of park. This condition may be caused by
chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR
BEFORE 01/23/2007. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 01/23/2007.
SERVICE PROCEDURE
1. Check the electrical system and make sure the shifter is getting power from the BOO switch
(actuate brake to confirm switch signal is getting to the shifter assembly).
2. Confirm the wiring in the shifter is ok (connections are made, no cut wires).
3. If there are no issues with wiring or other electrical components, follow Workshop Manual,
Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever
Cable Adjustment procedures to replace the Transmission Selector.
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
070308A 2006-2007 1.0 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The
Transmission
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 07-3-8 > Feb > 07 > A/T - Manual Override Required To
Get Out of 'PARK' > Page 4637
Selector Lever Includes Time For Cable Adjustment (Do Not Use With 7210A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7210 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4643
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4644
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4645
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4646
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4647
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4648
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 4649
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T Manual Override Required to Shift From PARK
Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required to Shift From PARK
TSB 07-12-9
06/25/07
INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE
OUT OF PARK - VEHICLES BUILT ON OR BEFORE 11/14/2006
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer, Mountaineer
This article supersedes TSB 07-11-12 to update the production fix date.
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on
or before 11/14/2006 may exhibit an intermittent condition where the shifter may require the use of
the manual override function to get the shifter out of park. This condition may be caused by
chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR
BEFORE 11/14/2006. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 11/14/2006.
SERVICE PROCEDURE
1. Check the electrical system and make sure the shifter is getting power from the BOO switch
(actuate brake to confirm switch signal is getting to the shifter assembly).
2. Confirm the wiring in the shifter is okay (connections are made, no cut wires).
3. If there are no issues with wiring or other electrical components, follow Workshop Manual,
Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever
Cable Adjustment procedures to replace the Transmission Selector.
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
071209A 2006-2007 1.0 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The
Transmission Selector Lever Includes
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T Manual Override Required to Shift From PARK > Page 4654
Time For Cable Adjustment (Do Not Use With 7210A)
MT071209 Claim Additional Diagnosis Actual
Or Labor Performed As Time
Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
7210 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T Manual Override Required To Get Out of 'PARK'
Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required To Get Out of 'PARK'
TSB 07-3-8
02/19/07
INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE
OUT OF PARK
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer, Mountaineer
This article supersedes TSB 06-25-10 to update the vehicle model years.
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on
or before 1/23/2007 may exhibit an intermittent condition where the shifter may require the use of
the manual override function to get the shifter out of park. This condition may be caused by
chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR
BEFORE 01/23/2007. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 01/23/2007.
SERVICE PROCEDURE
1. Check the electrical system and make sure the shifter is getting power from the BOO switch
(actuate brake to confirm switch signal is getting to the shifter assembly).
2. Confirm the wiring in the shifter is ok (connections are made, no cut wires).
3. If there are no issues with wiring or other electrical components, follow Workshop Manual,
Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever
Cable Adjustment procedures to replace the Transmission Selector.
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
070308A 2006-2007 1.0 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The
Transmission
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T Manual Override Required To Get Out of 'PARK' > Page 4659
Selector Lever Includes Time For Cable Adjustment (Do Not Use With 7210A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7210 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T - Manual
Override Required to Shift From PARK
Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required to Shift From PARK
TSB 07-12-9
06/25/07
INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE
OUT OF PARK - VEHICLES BUILT ON OR BEFORE 11/14/2006
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer, Mountaineer
This article supersedes TSB 07-11-12 to update the production fix date.
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on
or before 11/14/2006 may exhibit an intermittent condition where the shifter may require the use of
the manual override function to get the shifter out of park. This condition may be caused by
chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR
BEFORE 11/14/2006. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 11/14/2006.
SERVICE PROCEDURE
1. Check the electrical system and make sure the shifter is getting power from the BOO switch
(actuate brake to confirm switch signal is getting to the shifter assembly).
2. Confirm the wiring in the shifter is okay (connections are made, no cut wires).
3. If there are no issues with wiring or other electrical components, follow Workshop Manual,
Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever
Cable Adjustment procedures to replace the Transmission Selector.
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
071209A 2006-2007 1.0 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The
Transmission Selector Lever Includes
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-12-9 > Jun > 07 > A/T - Manual
Override Required to Shift From PARK > Page 4665
Time For Cable Adjustment (Do Not Use With 7210A)
MT071209 Claim Additional Diagnosis Actual
Or Labor Performed As Time
Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
7210 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T - Manual
Override Required To Get Out of 'PARK'
Shifter A/T: All Technical Service Bulletins A/T - Manual Override Required To Get Out of 'PARK'
TSB 07-3-8
02/19/07
INTERMITTENT CONDITION - SHIFTER REQUIRES MANUAL OVERRIDE TO GET VEHICLE
OUT OF PARK
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer, Mountaineer
This article supersedes TSB 06-25-10 to update the vehicle model years.
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer and 2007 Explorer Sport Trac vehicles built on
or before 1/23/2007 may exhibit an intermittent condition where the shifter may require the use of
the manual override function to get the shifter out of park. This condition may be caused by
chemicals migrating from the shifter lubricant, and being deposited on the shifter switch contacts.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
THIS TSB SHOULD BE PERFORMED ON 2006 VEHICLES AND 2007 VEHICLES BUILT ON OR
BEFORE 01/23/2007. THIS TSB DOES NOT APPLY TO VEHICLES BUILT AFTER 01/23/2007.
SERVICE PROCEDURE
1. Check the electrical system and make sure the shifter is getting power from the BOO switch
(actuate brake to confirm switch signal is getting to the shifter assembly).
2. Confirm the wiring in the shifter is ok (connections are made, no cut wires).
3. If there are no issues with wiring or other electrical components, follow Workshop Manual,
Section 307-05, Removal and Installation of the Transmission Selector Lever and Selector Lever
Cable Adjustment procedures to replace the Transmission Selector.
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
070308A 2006-2007 1.0 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac 5R555/6R60 Transmission: Replace The
Transmission
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 07-3-8 > Feb > 07 > A/T - Manual
Override Required To Get Out of 'PARK' > Page 4670
Selector Lever Includes Time For Cable Adjustment (Do Not Use With 7210A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7210 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement > Page 4676
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement > Page 4677
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement > Page 4678
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement > Page 4679
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement > Page 4680
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement > Page 4681
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Shifter A/T: > 09B11 > Jan > 10 > Campaign - A/T
Shift Lever Circuit Board Replacement > Page 4682
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever
Shifter A/T: Service and Repair Selector Lever
Selector Lever
Selector Lever
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
selector lever cable from the selector lever.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4685
3. Disconnect the selector lever cable from the selector lever housing.
4. Disconnect the electrical connector.
5. Disconnect the wiring harness from the selector lever housing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4686
6. Remove the 4 nuts and remove the selector lever housing from the vehicle.
Installation
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever
cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is
correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the
cable end is correctly installed.
1. Install the selector lever housing.
^ Tighten to 9 Nm (80 inch lbs.)
2. Connect the wiring harness to the selector lever housing.
3. Connect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4687
4. Install the selector lever cable onto the selector lever housing.
5. Connect the selector lever cable onto the selector lever.
6. Install the front floor console. For additional information, refer to Console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4688
Shifter A/T: Service and Repair Selector Lever Knob
Selector Lever Knob
Selector Lever Knob
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
transmission control (TC) switch electrical connector and feed the wire through the selector lever
housing.
3. Slide the selector lever lower trim cover downward.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4689
4. Remove the set screw and remove the selector lever knob while routing the TC switch harness
out of the selector lever housing.
Installation
1. CAUTION: Do not overtighten the set screw or damage to the selector lever knob may occur.
Install the selector lever knob and set screw while routing the TC switch harness through the
selector lever housing. ^
Tighten to 3 Nm (27 inch lbs.)
2. Slide the selector lever lower trim cover upward.
3. Feed the wire through the selector lever housing and connect the TC switch electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4690
4. Install the front floor console. For additional information, refer to Console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4691
Shifter A/T: Service and Repair Selector Lever Bezel
Selector Lever Bezel
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
transmission control (TC) switch electrical connector and feed the wire through the selector lever
housing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4692
3. Slide the selector lever lower trim cover downward.
4. Remove the set screw and remove the selector lever knob while routing the TC switch harness
out of the selector lever housing.
5. Remove the bezel from the selector lever housing.
Installation
1. Install the bezel onto the selector lever housing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair > Selector Lever > Page 4693
2. CAUTION: Do not overtighten the set screw or damage to the selector lever knob may occur.
Install the selector lever knob and set screw while routing the TC switch harness through the
selector lever housing. ^
Tighten to 3 Nm (27 inch lbs.)
3. Slide the selector lever lower trim cover upward.
4. Feed the wire through the selector lever housing and connect the TC switch electrical connector.
5. Install the front floor console. For additional information, refer to Console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
Selector Lever Cable Adjustment - 6R60
1. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Place the selector lever in the PARK position. 3. Move the
selector lever 3 detents. This should be the (D) position. 4. Remove the cable shield by prying on
the side of the shield closest to the boot, then sliding the shield away from the boot.
5. Disconnect the selector lever cable from the manual control lever.
6. Rotate the manual lever clockwise until the travel stops. Then rotate the manual lever
counterclockwise 3 detents. This should be the (D)
position.
7. With the selector lever cable end disconnected, unlock the tab on the selector lever cable end by
sliding it up.
8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the cable end is
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4698
snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable
to click in place. Pull back on the selector lever cable to make sure that it is locked into the bracket.
Also make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back
on the selector lever cable end to make sure that the cable end is correctly installed.
Carry out these adjustments on the selector lever cable end: 1
Make sure that the selector lever cable end slides forward and backward.
2 Connect the selector lever cable end onto the manual control lever.
3 Lock the selector lever cable end into place by pressing the lock tab down.
9. NOTE: If the shield is loose on the cable, install a new cable shield.
Install and secure the cable shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4699
Shift Cable: Service and Repair
Selector Lever Cable
Vehicles Equipped with a 6R60 Transmission
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4700
Vehicles Equipped with a 5R55S Transmission
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the center console left side panel.
3. With the selector lever in PARK, disconnect the selector lever cable from the selector lever.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4701
4. Disconnect the selector lever cable from the selector lever housing.
5. Pull the cable and grommet through the floorpan.
Vehicles equipped with a 6R60 transmission
6. Remove the cable shield by prying on the shield closest to the boot, then sliding the shield away
from the boot.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4702
7. Unlock the lock tab and disconnect the selector lever cable end from the transmission manual
lever.
8. Disconnect the selector lever cable from the bracket and remove the cable.
Vehicles equipped with a 5R55S transmission
9. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the
shield away from the boot.
10. Unlock the lock tab and disconnect the selector lever cable end from the transmission manual
lever.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4703
11. Disconnect the selector lever cable from the bracket and remove the cable.
Installation
Vehicles equipped with a 6R60 transmission
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever
cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is
correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the
cable end is correctly installed.
1. Install the selector lever cable into the bracket.
2. Connect the selector lever cable end onto the transmission manual lever and lock the lock tab.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4704
3. NOTE: If the shield is loose, install a new shield.
Install the cable shield.
Vehicles equipped with a 5R55S transmission
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever
cable into the bracket and listen for the cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the bracket. Also make sure that the selector lever cable end is
correctly installed onto the ball stud. Pull back on the selector lever cable end to make sure that the
cable end is correctly installed.
4. Install the selector lever cable into the bracket.
5. Connect the selector lever cable end onto the transmission manual lever.
6. NOTE: If the shield is loose, install a new shield.
Install the cable shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4705
All vehicles
7. Push the cable and grommet through the floorpan.
8. Connect the selector lever cable onto the selector lever housing.
9. Connect the selector lever cable onto the selector lever.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4706
10. Install the center console left side panel.
11. Verify the engine will start in PARK and NEUTRAL and the reversing lamps illuminate in
REVERSE. If not, readjust the selector lever cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Throttle Position Sensor/Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4711
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4712
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4713
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4714
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4715
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4716
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4717
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4718
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4719
Throttle Position Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4720
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4721
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4722
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4723
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4724
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4725
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4726
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Position
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4727
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications
Torque Converter: Specifications
Stall Speed
Stall Speed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications > Page 4731
Torque Converter: Description and Operation
Torque Converter
The torque converter is a 3-element unit containing a 3-plate clutch. The clutch can be controlled
and engaged in any gear 2 to 6. Calibration parameters may be set to allow lockup in a higher gear
only. The clutch is applied by removing fluid pressure from one side of the plate. The torque
converter transmits and multiplies torque. The torque converter includes these 3 elements: ^
Impeller assembly
^ Turbine assembly
^ Reactor assembly
The standard torque converter components operate as follows: ^
Rotation of the converter housing and impeller set the fluid in motion.
^ The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain
through the input shaft.
^ The reactor redirects fluid going back into the impeller, allowing for torque multiplication.
^ Power is transmitted from the torque converter to the planetary gearsets and other components
through the input shaft.
Torque Converter Clutch
The torque converter clutch is a device that reduces slip in the torque converter and, therefore,
helps to keep fuel consumption to a minimum.
The torque converter clutch is engaged and released by the control system.
Pressure at the torque converter clutch piston is determined by an electronic pressure control
valve.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Torque Converter Diagnosis
Torque Converter: Testing and Inspection Torque Converter Diagnosis
Torque Converter Diagnosis
Special Tool(s)
Prior to torque converter installation, all diagnostic procedures must be followed. This is to prevent
the unnecessary installation of good torque converters. Only after a complete diagnostic evaluation
can the decision be made to install a new torque converter.
Begin with the normal diagnostic procedures as follows: 1. Preliminary inspection. 2. Know and
understand the customer's concern. 3. Verify the condition - carry out the torque converter
operation test. See: Torque Converter Operation Test 4. Carry out diagnostic procedures.
^ Carry out on-board diagnostics. Repair all non-transmission related DTCs first.
- Repair all transmission-related DTCs.
- Rerun on-board diagnostics to verify repair.
^ Carry out Stall Speed Test. See: Transmission Control Systems/Testing and
Inspection/Component Tests and General Diagnostics/Special Testing Procedures/Stall Speed
Test
^ Carry out Diagnostic Routines. Refer to Diagnosis By Symptom. See: Transmission Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom
Use the Diagnosis by Symptom to locate the appropriate routine that best describes the
symptom(s). The routine will list all possible components that may cause or contribute to the
symptom. Check each component listed; diagnose and repair as required before changing the
torque converter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 4734
Torque Converter: Testing and Inspection Torque Converter Operation Test
Torque Converter Operation Test
The Torque Converter Operation Test verifies that the torque converter clutch (TCC) control
system and the torque converter are operating correctly.
1. Carry out Quick Test with scan tool. Refer to Computers and Control Systems. Check for DTCs.
2. Connect a scan tool to the vehicle. 3. Bring the engine to normal operating temperature by
driving the vehicle at highway speeds for approximately 15 minutes in D position. 4. After normal
operating temperature is reached, maintain a constant speed of about 56 km/h (35 mph) in 5th
gear for 10 seconds. 5. Release the accelerator pedal and monitor the scan tool TP voltage to
approximately 1.25 volts or 30% throttle. 6. Monitor the TCC and engine speed PID. The TCC
should release and engine rpms should increase before the 5-4 shift occurs.
NOTE: This is a list of common vehicle concerns that have been misdiagnosed as TCC shudder.
For diagnosis of these items, refer to the appropriate information and Computers and Control
Systems.
^ Spark plugs - check for cracks, high resistance or broken insulators
^ Plug wires
^ Fuel injector - filter may be plugged
^ Fuel contamination - engine driveability concerns
^ Exhaust gas recirculation (EGR) valve - valve may let in too much exhaust gas and cause engine
to run lean
^ Vacuum leak - engine will not get correct air/fuel mixture
^ Manifold absolute pressure (MAP)/mass air flow (MAF) sensor - incorrect air/fuel mixture
^ Heated oxygen sensor (HO2S) - too rich/lean air/fuel mixture
^ Fuel pressure - may be too low
^ Engine mounts - loose/damaged mounts can cause vibration concerns
^ Axle joints - check for vibration
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 4735
Torque Converter: Testing and Inspection Torque Converter
Torque Converter
1. A new or remanufactured torque converter must be installed if one or more of these statements
is true:
^ A torque converter malfunction has been determined based on complete diagnostic procedures.
^ Converter rivets, impeller hub or bushing are damaged.
^ Discoloration (due to overheating).
^ Evidence of transmission assembly or fluid contamination due to these transmission or converter
failure modes: Major metallic failure.
- Multiple clutches or clutch plate failures.
- Sufficient component wear which results in metallic contamination.
- Internal torque converter contamination present. For additional information, refer to Torque
Converter Contamination Inspection. See: Testing and Inspection/Component Tests and General
Diagnostics/Torque Converter Contamination Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 4736
Torque Converter: Testing and Inspection Torque Converter Contamination Inspection
Torque Converter Contamination Inspection
Material
CAUTION: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter
or transmission, damage will occur. Use only clean automatic transmission fluid designated for the
transmission and converter being serviced.
1. If a new or remanufactured torque converter is not being installed, these steps must be
completed. 2. With the torque converter on a bench, pour a small amount of transmission fluid from
the torque converter onto an absorbent white tissue or
through a paper filter and examine the fluid.
3. NOTE: The factory fill fluid is red.
Observe the color and odor of the fluid. The fluid should be red, not brown or black. Odor may
indicate an overheating condition such as clutch disc or band failure.
4. Examine the stain on the tissue for evidence of particles (specks of any kind). Examine the fluid
level indicator for signs of antifreeze (gum or
varnish). If particles are present in the fluid, a new torque converter must be installed.
5. If there are no particles or contamination present, drain the remainder of the transmission fluid
from the torque converter. 6. Add 1.9L (2 qt) of clean automatic transmission fluid into the converter
and agitate by hand. 7. Thoroughly drain the fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4741
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4742
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4743
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4744
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4745
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4746
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4747
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4748
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4749
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4750
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4751
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4752
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4753
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4754
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4755
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4756
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4757
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications
Transmission Cooler: Mechanical Specifications
Torque Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications > Page 4762
Transmission Cooler: Capacity Specifications
General Specifications
General Specifications
General Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications > Page 4763
Transmission Cooler: Fluid Type Specifications
General Specifications
General Specifications
General Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Transmission Cooling
CAUTION: Whenever a transmission has been disassembled to install new parts, a new
transmission fluid cooler must be installed and the transmission fluid cooler tubes must be cleaned
and backflushed.
NOTE: Cleaning and backflushing the transmission fluid cooling system (along with normal
cleaning and inspection procedures, as outlined during disassembly and assembly) will keep
contamination from reentering the transmission and causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and transmission fluid
cooler. These contaminants are a major cause of recurring transmission troubles and must be
removed from the system before the transmission is put back in use.
Inspection and Verification
When fluid leakage is found in the fluid cooler, install a new fluid cooler.
When there is evidence of transmission assembly or fluid contamination due to these transmission
failure modes, install a new fluid cooler. ^
Major metallic failure
^ Multiple clutches or clutch plate failure
^ Sufficient component wear which results in metallic contamination
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4766
Transmission Cooler: Symptom Related Diagnostic Procedures
Symptom Chart
Symptom Chart
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4767
Transmission Cooler: Component Tests and General Diagnostics
Transmission Fluid Cooler
CAUTION: Whenever a transmission has been disassembled to install new parts, the transmission
fluid cooler and transmission fluid cooler tubes must be cleaned and backflushed. Use a torque
converter/oil cooler cleaner.
NOTE: Cleaning and backflushing the transmission fluid cooling system, along with following all the
normal cleaning and inspection procedures during disassembly and reassembly, will keep
contaminants from entering the transmission, causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and transmission fluid
cooler. These contaminants are a major cause of recurring transmission troubles and must be
removed from the system before the transmission is put back into use.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures
Transmission Cooler: Procedures
Transmission Fluid Cooler - Backflushing and Cleaning
Material
CAUTION: When internal damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter and the transmission fluid cooler. These contaminates
are a major cause of recurring transmission concerns. To prevent further concerns, remove these
contaminates from the cooler lines and install a new cooler before placing the transmission in use.
CAUTION: Do not attempt to install an in-line transmission fluid filter on this vehicle, damage to the
cooling system or transmission could occur.
1. Install a new transmission fluid cooler if any fluid leaks are indicated or a major metallic failure is
indicated. 2. Using a suitable torque converter/fluid cooler cleaner, flush the fluid cooler and lines.
3. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting
them to the cleaner.
Connect the cleaner pressure and return lines appropriately. 1
Connect the pressure line to the fluid cooler inlet tube.
2 Connect the return line to the fluid cooler outlet tube.
3 Place the outlet end of the return line in the fluid tank reservoir.
4. NOTE: Cycling the fluid pump ON and OFF will help dislodge contaminants in the cooler system.
Switch the fluid pumps ON. Allow the fluid to circulate a minimum of 5 minutes.
5. Switch the fluid pump OFF. 6. Disconnect the cleaner pressure line at the fluid cooler tube. 7.
Using compressed air, blow through the fluid cooler inlet tube until all fluid is removed. 8. Remove
the rubber hoses from the fluid cooler tubes.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4770
Transmission Cooler: Removal and Replacement
Auxiliary Transmission Fluid Cooler
Material
Removal
Mountaineer
1. Remove the grille fasteners and the grille.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4771
Explorer
2. Remove the bumper cover.
All vehicles
3. Remove the inner grille air deflector.
4. Push the lower air deflector down past the transmission fluid cooler.
5. Disconnect the transmission fluid cooler hoses.
^ Remove and discard the transmission fluid cooler hoses and the clamps.
6. Remove the upper transmission fluid cooler bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4772
7. Remove the lower transmission fluid cooler bolts and the transmission fluid cooler.
Installation
All vehicles
1. Install the transmission fluid cooler and the lower transmission fluid cooler bolts.
^ Tighten to 7 Nm (62 inch lbs.)
2. Install the upper transmission fluid cooler bolt.
^ Tighten to 7 Nm (62 inch lbs.)
3. NOTE: Clean the cooler tube stems with degreaser prior to installing the hoses.
Using new hoses and clamps, install the transmission fluid cooler hoses.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Service and Repair > Procedures > Page 4773
4. Push the lower air deflector back into place.
5. Install the inner grille air deflector.
Mountaineer
6. Install the grille and the fasteners.
Explorer
7. Install the bumper cover.
All vehicles
8. Fill and check the transmission fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Mode Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4781
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4782
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4783
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4784
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4785
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4786
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4787
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4788
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4789
Transmission Mode Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4790
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4791
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4792
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4793
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4794
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4795
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4796
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4797
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation > Transmission Control (TC) Switch
Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch
Transmission Control (TC) Switch
The transmission control (TC) switch is a momentary contact switch located on the selector lever
knob. Pushing the TC switch will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the
instrument panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation > Transmission Control (TC) Switch > Page 4800
Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS)
TRANSMISSION CONTROL SWITCH (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation > Page 4801
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Removal
1. Remove the transmission selector lever knob.
2. Remove the transmission control switch from the knob.
Installation
1. Install the transmission control switch into the knob.
2. Install the transmission selector lever knob.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4806
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4807
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4808
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4809
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4810
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4811
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4812
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4813
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4814
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4815
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4816
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4817
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4818
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4819
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4820
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4821
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4822
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4823
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test
Port, A/T > Component Information > Locations
Transmission Pressure Test Port: Locations
Air Pressure Test
Air Pressure Test
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4831
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4832
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4833
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4834
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4835
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4836
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4837
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4838
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4839
Transmission Speed Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4840
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4841
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4842
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4843
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4844
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4845
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4846
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4847
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4848
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4849
C164
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4854
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4855
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4856
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4857
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4858
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4859
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4860
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4861
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4862
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4863
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4864
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4865
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4866
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4867
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4868
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4869
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4870
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Valve Body: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4879
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4880
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 07-6-3 > Apr > 07 > A/T 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4881
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 07-6-3 > Apr > 07
> A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Valve Body: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 07-6-3 > Apr > 07
> A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4887
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 07-6-3 > Apr > 07
> A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4888
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 07-6-3 > Apr > 07
> A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 4889
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4890
Valve Body: Locations
Check Ball Location
Check Ball Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4891
Valve Body: Diagrams
Mechatronic Assembly
Mechatronic (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4892
Mechatronic (Part 2)
Mechatronic Upper Half (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4893
Mechatronic Upper Half (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4894
Mechatronic Lower Half (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4895
Mechatronic Lower Half (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 4896
Mechatronic Lower Half (Part 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement
Valve Body: Removal and Replacement
Mechatronic Assembly
Removal
NOTE: If a new or the existing Mechatronic assembly is installed, the transmission control module
(TCM) will need to be reflashed to the latest level calibration available.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on
the connector.
3. Remove the fill plug fluid level indicator assembly located on the passenger side front portion of
the transmission case. Removal of the plug will
relieve any vacuum that might have built up in the transmission. This will allow the fluid pan to be
easily removed when the bolts are removed.
4. Remove the transmission fluid pan and allow the fluid to drain.
5. Remove the fluid pan gasket.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4899
6. Remove and discard the transmission fluid filter.
7. Pull the release tab and pull down on the bulkhead connector retainer.
8. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM.
Electrostatic discharge may occur and
may cause damage to the Mechatronic unit.
With the release tab down, pull the outer shell of the bulkhead electrical connector out of the TCM.
9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM.
Electrostatic discharge may occur and
may cause damage to the Mechatronic unit.
Pull the bulkhead electrical connector out of the transmission.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4900
10. NOTE: During removal of the Mechatronic, the thermal bypass valve, pump adapter seal and
one or more center support seals may become
dislodged. Save these components for re-use during assembly.
Remove the 11 bolts from the Mechatronic assembly and remove the Mechatronic assembly.
Installation
NOTE: Before reinstalling the Mechatronic assembly into the transmission case, verify presence
and correct orientation of the thermal bypass valve, pump adapter seal and center support seals.
Also note that one or more of the center support seals may have remained in the Mechatronic
assembly during removal and should be installed into the transmission case at this time.
1. Verify the 4 rubber feed tubes for the center support are in place.
1 Black feed tube.
2 Green feed tube.
3 Blue feed tube.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4901
2. Verify the rubber adapter is in place.
3. Verify the thermal bypass valve is in the case.
4. Position the Mechatronic assembly in place and loosely install the 11 bolts.
1 Align the manual valve and control lever linkage.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4902
5. Tighten the Mechatronic bolts in the sequence shown.
^ Tighten to 6 Nm (53 inch lbs.)
6. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM.
Electrostatic discharge may occur and
may cause damage to the Mechatronic unit.
With the release tab down and unlocked, push the outer shell of the bulkhead electrical connector
into the transmission. Make sure that the bulkhead connector is fully seated into the TCM.
7. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place. Make
sure that the locking tab is securely locked.
8. Install a new transmission fluid filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4903
9. NOTE: The fluid pan gasket can be reused if not damaged.
Install the transmission fluid pan gasket if required.
10. Install the fluid pan and tighten the bolts in a crisscross pattern.
^ Tighten to 14 Nm (10 ft. lbs.)
11. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to
lock it in place.
12. Using the refill procedure, fill the transmission with clean automatic transmission fluid. 13. If a
new or the existing Mechatronic assembly is installed, the TCM will need to be reflashed to the
latest level calibration available.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4904
Valve Body: Overhaul
Mechatronic Assembly
Mechatronic (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4905
Mechatronic (Part 2)
Mechatronic Upper Half (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4906
Mechatronic Upper Half (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4907
Mechatronic Lower Half (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4908
Mechatronic Lower Half (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4909
Mechatronic Lower Half (Part 3)
Check Ball Location
Disassembly
CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission control module (TCM). An electrostatic discharge may occur and may cause damage
to the TCM/Mechatronic assembly.
NOTE: Make an identifying mark on each solenoid and the corresponding bore for correct
assembly.
NOTE: Solenoids may visually appear the same but their designs/functions are different. Caution
must be taken not to assemble the Mechatronics assembly incorrectly. Incorrect solenoid
installation will result in poor transmission shift quality.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4910
NOTE: Note where the 8 check balls, 6 solenoid dampers, 2 internal valves and springs and 2
internal filters are located for reassembly.
Mechatronic assembly upper half
1. Make an identifying mark on each solenoid and the corresponding bore for correct assembly.
2. Remove the 6 long bolts from the TCM unit.
3. Carefully separate the TCM from the Mechatronic assembly. 4. Remove 19 short bolts from the
Mechatronic assembly.
5. Separate the lower half of the Mechatronic assembly from the upper half of the Mechatronic
assembly. 6. Remove and discard the separator plate.
7. Remove from the Mechatronic assembly the clips, caps, valves and spring from each bore. Note
the location and order for reassembly. Refer to the
exploded views.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4911
8. Remove from the Mechatronic assembly the transmission control valves, check balls and filter
screens. Note the location and order for reassembly.
Refer to the exploded views.
9. Using clean mineral spirits, clean the upper half of the Mechatronic assembly.
Mechatronic assembly lower half
10. Remove the 8 solenoid bracket bolts and the solenoid bracket.
11. Remove the solenoids.
12. Remove from the Mechatronic assembly the clips, caps, valves and spring from each bore.
Note the location and order for reassembly. Refer to the
exploded views.
13. Using clean mineral spirits, clean the lower half of the Mechatronic assembly.
Assembly
CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the TCM. An
electrostatic discharge may occur and may cause damage to the TCM/Mechatronic assembly.
Mechatronic assembly upper half
1. NOTE: Many components and surfaces in the Mechatronic valve body are precision machined.
Careful handling during disassembly, cleaning,
inspection and assembly will prevent unnecessary damage to machined surfaces.
Install the clips, caps, valves and spring into each bore. Refer to the exploded views.
Mechatronic assembly lower half
2. NOTE: Many components and surfaces in the Mechatronic valve body are precision machined.
Careful handling during disassembly, cleaning,
inspection and assembly will prevent unnecessary damage to machined surfaces.
Install the clips, caps, valves and spring into each bore.
3. NOTE: Lubricate the O-ring seals of the solenoids with clean automatic transmission fluid when
installing them into the valve body.
Install the solenoids into their correct bores as indicated during disassembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4912
4. Install the solenoid bracket and the 8 bolts.
^ Tighten to 6 Nm (53 inch lbs.)
5. Install into the Mechatronic assembly the transmission control valves, check balls and filter
screens. Refer to the exploded views. 6. Install a new separator plate.
7. Assemble the lower half and the upper half of the Mechatronic assembly. 8. Install the 19 short
bolts into the Mechatronic assembly. Tighten the bolts in the sequence shown.
^ Tighten to 6 Nm (53 inch lbs.)
9. Carefully install the TCM onto the Mechatronic assembly.
10. Install the 6 long bolts into the TCM unit. Tighten the bolts in the sequence shown.
^ Tighten to 6 Nm (53 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Replacement > Page 4913
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 09-22-15 > Nov > 09 > A/T
Controls - MIL ON/Various A/T Solenoid DTC's
Wiring Harness: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 09-22-15 > Nov > 09 > A/T
Controls - MIL ON/Various A/T Solenoid DTC's > Page 4922
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
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-22-15 > Nov
> 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's
Wiring Harness: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-22-15 > Nov
> 09 > A/T Controls - MIL ON/Various A/T Solenoid DTC's > Page 4928
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
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Hydraulic Hose, Clutch > Component Information >
Tools and Equipment
Hydraulic Hose: Tools and Equipment
Clutch Line Fork
AST tool# 8008
Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This
tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford
Aerostar, Bronco II, Explorer, F150 and Ranger.
- For R and R of Hydraulic Clutch Lines
- Applicable to Ford Models with Manual Transmissions
- Steel Construction
- Black-Oxide Finish
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements
Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Tow
Capability/Service Kit Requirements
TSB 06-7-1
04/17/06
NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS
FORD: 2004-2006 Focus 2004 F-150 Heritage 2004-2005 Explorer Sport Trac 2004-2006 Escape,
Explorer, F-150-350 Series, Ranger 2005-2006 Escape Hybrid 2007 Explorer Sport Trac
LINCOLN: 2006 Mark LT
MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 06-4-5 to update the vehicle neutral tow application chart.
ISSUE Various vehicles are neutral tow capable. Refer to the following chart to determine neutral
tow capability for specific vehicle applications, and to determine if a Service Kit is required to make
the vehicle neutral tow capable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements > Page 4937
ACTION Review the neutral tow application chart (Figure 1) and order the kit, if applicable.
Reprogramming of various modules may be required for some installations. Installation instructions
are included with the kit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Component Information > Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements > Page 4938
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Front Differential
Differential Oil Capacity
Refill .....................................................................................................................................................
........................................................... 2.7 pts. (1.3L)
Rear Differential
Differential Oil Capacity
Refill .....................................................................................................................................................
........................................................... 3.5 pts. (1.7L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 4944
Fluid - Differential: Fluid Type Specifications
Front Differential
Differential Fluid Type
Type ................................................................................................................................................
Motorcraft SAE 80W-90 Premium Rear Axle Lubricant Ford Part Number .........................................
................................................................................................................................................
XY-80W90-QL Ford Specification .......................................................................................................
............................................................................... WSP-M2C197-A
Rear Differential
Differential Fluid Type
Type ................................................................................................................................. SAE
75W-140 High Performance Synthetic Rear Axle Lubricant
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Page 4945
Fluid - Differential: Service and Repair
Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear
Differential Draining and Filling
Special Tool(s)
Material
Fluid Check
1. NOTE: Before removing, clean the area around the filler plug.
Remove the fill plug.
Fluid Drain and Fill
1. Remove the drain plug. 2. Clean and install the drain plug.
^ Tighten to 34 Nm (25 ft. lbs.)
3. Fill the axle to the bottom of the fill plug hole. 4. Install the fill plug.
^ Tighten to 34 Nm (25 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear
Differential Output Shaft Bearing: Service and Repair Rear Drive Axle/Differential - Ford 8.8-Inch
Ring Gear
Stub Shaft Pilot Bearing and Seal
Special Tool(s)
Material
Removal
1. Remove the halfshaft assembly.
2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool
on the stub shaft pilot bearing oil seal.
Using the special tools, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1
Firmly engage the tangs of the special tool on the stub shaft pilot bearing.
2 Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4951
3. Inspect the stub shaft pilot bearing oil seal journal for rust, nicks and scratches. Polish the seal
journal surface with fine crocus cloth, if necessary.
Installation
1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing.
2. CAUTION: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without
the correct tools can result in early stub
shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes
cocked in the bore during installation, remove it and install a new stub shaft pilot bearing.
Place the stub shaft pilot bearing onto the special tools.
3. Install the stub shaft pilot bearing into the rear axle housing bore.
4. NOTE: Do not disassemble the new oil seal.
NOTE: Use a tool like the Lisle LIS 17850 to avoid interference with the suspension components.
Install the stub shaft pilot bearing oil seal onto a suitable seal installer.
5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft
pilot bearing oil seal flush in the differential
housing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4952
6. Remove and discard the halfshaft excluder seal, if equipped.
7. Install the halfshaft assembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4953
Differential Output Shaft Bearing: Service and Repair Front Drive Axle/Differential - Dana 30
Stub Shaft Pilot Bearing and Seal
Stub Shaft Pilot Bearing and Seal
Special Tool(s) (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4954
Special Tool(s) (Part 2)
Material
Removal
Both sides
1. Remove the halfshafts.
Right side
2. Remove the axle shaft.
Both sides
3. Using the special tool and a suitable slide hammer to remove the stub shaft oil seals.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4955
4. Using the special tool and a slide hammer, remove the stub shaft pilot bearings or bushings, as
equipped.
5. Clean the bearing and seal surfaces of any foreign material.
Installation
Right side
1. Using the special tools, install the stub shaft pilot bearing or bushing, as equipped.
2. Using the special tools, install the stub shaft oil seals.
3. CAUTION: Care should be taken not to damage the axle seal surface.
Install the axle shaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4956
Left side
4. Using the special tools, install the stub shaft bearing or bushing, as equipped.
5. Using the special tools, install the stub shaft seal.
Both sides
6. Refill the front drive axle to the correct level with lubricant. 7. Install the halfshafts.
Drive Pinion Flange and Seal
Drive Pinion Flange and Seal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4957
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4958
Removal
CAUTION: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing
preload during assembly.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during
the pinion bearing preload recording and
adjustment.
Remove the front tires and wheels.
3. Remove the front driveshaft.
4. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose.
Provide a suitable support.
Remove the disc brake caliper anchor bolts, then remove the disc brake caliper and disc brake
caliper anchor as an assembly. ^
Using mechanic's wire, position and support the disc brake caliper and disc brake caliper anchor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4959
5. Measure and record the pinion bearing preload.
^ Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion
gear rotation.
6. Index-mark the pinion flange and the pinion gear stem.
7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
8. Using the special tool, remove the pinion flange.
9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts
the pinion bearing cone, pinion nut counterbore
and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.
10. Using gripping pliers and a hammer, remove the drive pinion oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4960
11. Remove the drive pinion oil slinger and the outer pinion bearing.
12. Remove and discard the collapsible spacer. 13. Verify the splines on the pinion stem are free of
burrs. If burrs are evident, remove them with a fine crocus cloth. 14. Clean the drive pinion oil seal
bore.
Installation
1. Install a new collapsible spacer. 2. Install the outer pinion bearing and the drive pinion oil slinger.
3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant.
NOTE: Drive pinion oil seal must be fully seated all the way around or drive pinion oil seal damage
will occur.
Using the special tool, install the drive pinion oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4961
4. CAUTION: Never use a hammer or install the pinion flange with power tools.
NOTE: Lubricate the pinion flange splines with axle lubricant.
Align the index marks and using the special tool, install the pinion flange.
5. Install the new pinion nut. Only hand-tighten the pinion nut at this time.
6. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new
collapsible spacer and pinion nut if pinion
bearing preload reduction is necessary.
Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing
preload. ^
Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating
correctly. Take frequent pinion bearing preload readings by rotating the pinion gear with a Nm
torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken
during removal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential
Output Shaft Bearing > Component Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring
Gear > Page 4962
7. Install the disc brake caliper and disc brake caliper anchor as an assembly, then the disc brake
caliper anchor bolts.
^ Tighten to 108 Nm (80 ft. lbs.)
8. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the
driveshaft can pinch the boot between the
shaft and the flange and cause the boot to tear.
CAUTION: Install the driveshaft with new bolts and washers and new bolts and universal joint
retainers. If new bolts are not available, coat the threads of the original bolts with Threadlock and
sealer.
Install the front driveshaft.
9. Install the front tires and wheels.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear
Pinion Flange: Service and Repair Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear
Drive Pinion Flange and Drive Pinion Seal
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4967
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the rear wheel and tire assemblies.
3. CAUTION: Remove the rear brake calipers to prevent drag during the pinion bearing preload
adjustment.
CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are not repairable. Use silicone brake caliper grease
or equivalent for re-lubing the caliper slide pins. Other greases can swell the guide pin boots,
resulting in contamination and accelerated corrosion and wear of the caliper slide pin mechanism.
CAUTION: Do not allow the calipers to hang from the brake hoses.
Remove the rear disc brake caliper assembly. 1
Remove the disc brake caliper bolts.
2 Lift the rear disc brake caliper off the knuckle. ^
Support the caliper assembly with a length of mechanic's wire.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4968
4. Index-mark the driveshaft flange and pinion flange for correct alignment during installation.
5. NOTE: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft
flange bolts with Threadlock and sealer.
Remove the driveshaft flange bolts.
6. CAUTION: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the
driveshaft or any of its components to
disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable
tool, to disconnect the driveshaft flange from the pinion flange.
Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange, then using
mechanic's wire, position the driveshaft aside.
7. Install a Nm (inch pound) torque wrench on the pinion nut and record the torque necessary to
maintain rotation of the drive pinion gear through
several revolutions.
8. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4969
9. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation.
10. Using the special tool, remove the pinion flange.
11. If necessary, use a screwdriver to force up the metal flange of the pinion seal. Install gripping
pliers and strike with a hammer to remove the drive
pinion seal.
Installation
1. If removed, lubricate the lips of the new drive pinion seal with grease.
2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove the drive
pinion seal and install a new drive pinion
seal.
NOTE: Always install a new drive pinion seal when removed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4970
If the drive pinion seal was removed, use the special tool to install a new drive pinion seal.
3. Inspect the pinion flange seal journal for rust, nicks and scratches prior to installing the pinion
flange. Polish the seal journal with fine crocus
cloth, if necessary.
4. Lubricate the pinion flange splines with grease.
5. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
6. Using the special tools, install the pinion flange.
7. CAUTION: Do not under any circumstance loosen the pinion nut to reduce drive pinion bearing
preload. If it is necessary to reduce
drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.
Tighten the pinion nut to set the drive pinion bearing preload. ^
Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly.
Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm
(inch pound) torque wrench.
^ Rotational torque must be at least the recorded original torque plus a maximum of 5 inch-pounds.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4971
8. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the
correct disc brake caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: Use the brake disc pad spreader to spread pads for reassembly.
Install the disc brake caliper, then install the disc brake caliper bolts. ^
Tighten to 32 Nm (24 ft. lbs.)
9. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make
sure that the yoke seats squarely on the
pinion flange, tighten the driveshaft flange bolts evenly in a cross-pattern as shown.
CAUTION: If new driveshaft flange bolts are not available, coat the threads of the original
driveshaft flange bolts with Threadlock and sealer.
Install the driveshaft, then the driveshaft flange bolts. ^
Tighten the bolts in the order shown to 112 Nm (83 ft. lbs.)
10. Install the rear wheel and tire assemblies.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4972
Pinion Flange: Service and Repair Front Drive Axle/Differential - Dana 30
Drive Pinion Flange and Seal
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4973
Removal
CAUTION: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing
preload during assembly.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. NOTE: The front wheels and tires and brake calipers must be removed to prevent drag during
the pinion bearing preload recording and
adjustment.
Remove the front tires and wheels.
3. Remove the front driveshaft.
4. CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose.
Provide a suitable support.
Remove the disc brake caliper anchor bolts, then remove the disc brake caliper and disc brake
caliper anchor as an assembly. ^
Using mechanic's wire, position and support the disc brake caliper and disc brake caliper anchor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4974
5. Measure and record the pinion bearing preload.
^ Using a Nm torque wrench, rotate the pinion gear. Measure the torque required to maintain pinion
gear rotation.
6. Index-mark the pinion flange and the pinion gear stem.
7. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
8. Using the special tool, remove the pinion flange.
9. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts
the pinion bearing cone, pinion nut counterbore
and drive pinion oil seal surface for nicks. Discard the pinion flange if damaged.
10. Using gripping pliers and a hammer, remove the drive pinion oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4975
11. Remove the drive pinion oil slinger and the outer pinion bearing.
12. Remove and discard the collapsible spacer. 13. Verify the splines on the pinion stem are free of
burrs. If burrs are evident, remove them with a fine crocus cloth. 14. Clean the drive pinion oil seal
bore.
Installation
1. Install a new collapsible spacer. 2. Install the outer pinion bearing and the drive pinion oil slinger.
3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant.
NOTE: Drive pinion oil seal must be fully seated all the way around or drive pinion oil seal damage
will occur.
Using the special tool, install the drive pinion oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4976
4. CAUTION: Never use a hammer or install the pinion flange with power tools.
NOTE: Lubricate the pinion flange splines with axle lubricant.
Align the index marks and using the special tool, install the pinion flange.
5. Install the new pinion nut. Only hand-tighten the pinion nut at this time.
6. CAUTION: Do not loosen the pinion nut to reduce pinion bearing preload. Install a new
collapsible spacer and pinion nut if pinion
bearing preload reduction is necessary.
Using the special tool to hold the pinion flange, tighten the pinion nut to set the pinion bearing
preload. ^
Tighten the pinion nut, rotating the pinion occasionally to make sure the pinion bearings are seating
correctly. Take frequent pinion bearing preload readings by rotating the pinion gear with a Nm
torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than the initial reading taken
during removal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4977
7. Install the disc brake caliper and disc brake caliper anchor as an assembly, then the disc brake
caliper anchor bolts.
^ Tighten to 108 Nm (80 ft. lbs.)
8. CAUTION: Always connect the front driveshaft to the axle first. Otherwise, the weight of the
driveshaft can pinch the boot between the
shaft and the flange and cause the boot to tear.
CAUTION: Install the driveshaft with new bolts and washers and new bolts and universal joint
retainers. If new bolts are not available, coat the threads of the original bolts with Threadlock and
sealer.
Install the front driveshaft.
9. Install the front tires and wheels.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear
Seals and Gaskets: Service and Repair Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear
Drive Pinion Flange and Drive Pinion Seal
Drive Pinion Flange and Drive Pinion Seal
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4982
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the rear wheel and tire assemblies.
3. CAUTION: Remove the rear brake calipers to prevent drag during the pinion bearing preload
adjustment.
CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are not repairable. Use silicone brake caliper grease
or equivalent for re-lubing the caliper slide pins. Other greases can swell the guide pin boots,
resulting in contamination and accelerated corrosion and wear of the caliper slide pin mechanism.
CAUTION: Do not allow the calipers to hang from the brake hoses.
Remove the rear disc brake caliper assembly. 1
Remove the disc brake caliper bolts.
2 Lift the rear disc brake caliper off the knuckle. ^
Support the caliper assembly with a length of mechanic's wire.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4983
4. Index-mark the driveshaft flange and pinion flange for correct alignment during installation.
5. NOTE: If new driveshaft flange bolts are not available, coat the threads of the original driveshaft
flange bolts with Threadlock and sealer.
Remove the driveshaft flange bolts.
6. CAUTION: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the
driveshaft or any of its components to
disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable
tool, to disconnect the driveshaft flange from the pinion flange.
Using a suitable tool as shown, disconnect the driveshaft flange from the pinion flange, then using
mechanic's wire, position the driveshaft aside.
7. Install a Nm (inch pound) torque wrench on the pinion nut and record the torque necessary to
maintain rotation of the drive pinion gear through
several revolutions.
8. Using the special tool to hold the pinion flange, remove and discard the pinion nut.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4984
9. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation.
10. Using the special tool, remove the pinion flange.
11. If necessary, use a screwdriver to force up the metal flange of the pinion seal. Install gripping
pliers and strike with a hammer to remove the drive
pinion seal.
Installation
1. If removed, lubricate the lips of the new drive pinion seal with grease.
2. CAUTION: If the drive pinion seal becomes misaligned during installation, remove the drive
pinion seal and install a new drive pinion
seal.
NOTE: Always install a new drive pinion seal when removed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4985
If the drive pinion seal was removed, use the special tool to install a new drive pinion seal.
3. Inspect the pinion flange seal journal for rust, nicks and scratches prior to installing the pinion
flange. Polish the seal journal with fine crocus
cloth, if necessary.
4. Lubricate the pinion flange splines with grease.
5. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
6. Using the special tools, install the pinion flange.
7. CAUTION: Do not under any circumstance loosen the pinion nut to reduce drive pinion bearing
preload. If it is necessary to reduce
drive pinion bearing preload, install a new differential drive pinion collapsible spacer and pinion nut.
Tighten the pinion nut to set the drive pinion bearing preload. ^
Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat correctly.
Take frequent drive pinion bearing preload readings by rotating the drive pinion gear with a Nm
(inch pound) torque wrench.
^ Rotational torque must be at least the recorded original torque plus a maximum of 5 inch-pounds.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4986
8. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the
correct disc brake caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: Use the brake disc pad spreader to spread pads for reassembly.
Install the disc brake caliper, then install the disc brake caliper bolts. ^
Tighten to 32 Nm (24 ft. lbs.)
9. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make
sure that the yoke seats squarely on the
pinion flange, tighten the driveshaft flange bolts evenly in a cross-pattern as shown.
CAUTION: If new driveshaft flange bolts are not available, coat the threads of the original
driveshaft flange bolts with Threadlock and sealer.
Install the driveshaft, then the driveshaft flange bolts. ^
Tighten the bolts in the order shown to 112 Nm (83 ft. lbs.)
10. Install the rear wheel and tire assemblies.
Stub Shaft Pilot Bearing and Seal
Stub Shaft Pilot Bearing and Seal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4987
Special Tool(s)
Material
Removal
1. Remove the halfshaft assembly.
2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the special tool
on the stub shaft pilot bearing oil seal.
Using the special tools, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1
Firmly engage the tangs of the special tool on the stub shaft pilot bearing.
2 Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4988
3. Inspect the stub shaft pilot bearing oil seal journal for rust, nicks and scratches. Polish the seal
journal surface with fine crocus cloth, if necessary.
Installation
1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing.
2. CAUTION: Installation of the stub shaft pilot bearing or stub shaft pilot bearing oil seal without
the correct tools can result in early stub
shaft pilot bearing or stub shaft pilot bearing oil seal failure. If the stub shaft pilot bearing becomes
cocked in the bore during installation, remove it and install a new stub shaft pilot bearing.
Place the stub shaft pilot bearing onto the special tools.
3. Install the stub shaft pilot bearing into the rear axle housing bore.
4. NOTE: Do not disassemble the new oil seal.
NOTE: Use a tool like the Lisle LIS 17850 to avoid interference with the suspension components.
Install the stub shaft pilot bearing oil seal onto a suitable seal installer.
5. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft
pilot bearing oil seal flush in the differential
housing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4989
6. Remove and discard the halfshaft excluder seal, if equipped.
7. Install the halfshaft assembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4990
Seals and Gaskets: Service and Repair Front Drive Axle/Differential - Dana 30
Stub Shaft Pilot Bearing and Seal
Special Tool(s) (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4991
Special Tool(s) (Part 2)
Material
Removal
Both sides
1. Remove the halfshafts.
Right side
2. Remove the axle shaft.
Both sides
3. Using the special tool and a suitable slide hammer to remove the stub shaft oil seals.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4992
4. Using the special tool and a slide hammer, remove the stub shaft pilot bearings or bushings, as
equipped.
5. Clean the bearing and seal surfaces of any foreign material.
Installation
Right side
1. Using the special tools, install the stub shaft pilot bearing or bushing, as equipped.
2. Using the special tools, install the stub shaft oil seals.
3. CAUTION: Care should be taken not to damage the axle seal surface.
Install the axle shaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Rear Drive Axle/Differential - Ford 8.8-Inch Ring Gear > Page 4993
Left side
4. Using the special tools, install the stub shaft bearing or bushing, as equipped.
5. Using the special tools, install the stub shaft seal.
Both sides
6. Refill the front drive axle to the correct level with lubricant. 7. Install the halfshafts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Mechanical Specifications
Axle Shaft Assembly: Mechanical Specifications
General Specifications
General Specifications
General Specifications
Torque Specifications
Torque Specifications
Torque Specifications
General Specifications
General Specifications
General Specifications
Torque Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Mechanical Specifications > Page 4999
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Mechanical Specifications > Page 5000
Axle Shaft Assembly: Capacity Specifications
Axle Lubricants and Capacities
Axle Lubricants and Capacities
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Specifications > Mechanical Specifications > Page 5001
Axle Shaft Assembly: Fluid Type Specifications
Axle Lubricants and Capacities
Axle Lubricants and Capacities
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Description and Operation > Front Drive Halfshafts
Axle Shaft Assembly: Description and Operation Front Drive Halfshafts
Front Drive Halfshafts
^ Inboard and outboard CV joints connect to a splined shaft. A circlip stopper holds the cross
groove inboard race assembly (inboard CV joint) together.
^ A circlip retains the splined inboard CV joint to the differential side gear on the LH halfshaft.
Install a new circlip every time the LH halfshaft is removed from the vehicle.
^ A circlip retains the splined RH inboard CV joint to an axle shaft. Install a new circlip on the axle
shaft every time the RH halfshaft is removed from the axle shaft.
^ A front axle wheel end nut secures the side shaft assembly (interconnecting shaft and outboard
CV joint) to the front hub. Install a new front axle wheel end nut every time you remove the
halfshaft from the vehicle.
Halfshaft Handling
CAUTION: Never pick up or hold the halfshaft by the inboard or outboard CV joint only.
NOTE: Only the inner CV joints are removable for installation of new CV boots and clamps. The
boots, grease and clamps are the only serviced parts of the halfshaft assembly. These are
available as a complete kit only.
Handle all halfshaft components carefully during removal and installation procedures. ^
The halfshaft assemblies are not repairable. Install new assemblies if worn/damaged.
^ To separate the halfshaft from the front hub, press the outboard CV joint from the front hub.
^ To separate the halfshaft from the differential, apply a load to the back face of the inboard CV
joint assembly to overcome the circlip.
^ Do not overangle the CV joints.
^ Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint
housing.
^ Never use a hammer to remove or install the halfshafts.
^ Never use the halfshaft assembly as a lever to position other components. Always support the
free end of the halfshaft.
^ Do not allow the boots to contact sharp edges or hot exhaust components.
^ Handle the halfshaft by the interconnecting shaft only to avoid pull-apart and potential damage to
the CV joints.
^ Do not drop assembled halfshafts. The impact can cut the boots from the inside without evidence
of external damage.
Wheel and Tire Balancing, Front
WARNING: Do not balance the front wheels and tires while mounted on the vehicle.
Hoisting
CAUTION: Use a frame-contact hoist only. Vehicle or component damage can result if other types
of hoists are used. Refer to Maintenance/Service and Repair.
Never raise the vehicle using the halfshafts as lift points.
Undercoating and Rustproofing
During undercoating and rustproofing procedures, protect the boots from the coating materials.
Foreign materials on the rubber boots will cause extreme advanced wear.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Description and Operation > Front Drive Halfshafts > Page 5004
Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts
Rear Drive Halfshafts
^ The RH and LH halfshafts are different lengths, with the RH halfshaft being the longer of the 2.
^ Inboard and outboard CV joints connect to a splined shaft. A circlip stopper holds the inboard
race assembly (inboard CV joint) together.
^ An axle circlip retains the splined inboard CV joint to the differential side gear. Install a new axle
circlip every time the halfshaft is removed from the vehicle.
^ A rear axle wheel end nut secures the side shaft assembly (interconnecting shaft and outboard
CV joint) to the rear hub. Install a new rear axle wheel end nut every time you remove the halfshaft
from the vehicle.
^ Install a new differential stub shaft seal every time the halfshaft is removed.
Halfshaft Handling
CAUTION: Never pick up or hold the halfshaft by the inboard or outboard CV joint only.
NOTE: Only the inner CV joints are removable for installation of new CV boots and clamps. The
boots and clamps are the only serviced parts of the halfshaft assembly.
Handle all halfshaft components carefully during removal and installation procedures. ^
The halfshaft assemblies are not repairable. Install new assemblies if worn/damaged.
^ To separate the halfshaft from the rear hub, press the outboard CV joint from the rear hub.
^ To separate the halfshaft from the differential, apply a load to the back face of the inboard CV
joint assembly to overcome the axle circlip.
^ Do not overangle the CV joints.
^ Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint
housing.
^ Never use a hammer to remove or install the halfshafts.
^ Never use the halfshaft assembly as a lever to position other components. Always support the
free end of the halfshaft.
^ Do not allow the boots to contact sharp edges or hot exhaust components.
^ Handle the halfshaft by the interconnecting shaft only to avoid pull-apart and potential damage to
the CV joints.
^ Do not drop assembled halfshafts. The impact can cut the boots from the inside without evidence
of external damage.
Wheel and Tire Balancing, Rear
WARNING: Do not balance the rear wheels and tires while mounted on the vehicle.
Hoisting
CAUTION: Use a frame-contact hoist only. Vehicle or component damage can result if other types
of hoists are used. For additional information, refer to Maintenance/Service and Repair.
Never raise the vehicle using the halfshafts as lift points.
Undercoating and Rustproofing
During undercoating and rustproofing procedures, protect the boots from the coating materials.
Foreign materials on the rubber boots will cause extreme advanced wear.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement
Axle Shaft Assembly: Removal and Replacement
Front Drive Halfshafts
Halfshaft
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5007
Removal and Installation
1. CAUTION: Do not loosen the front axle wheel end nut until after the wheel and tire assembly are
removed from the vehicle. Wheel
bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. Remove the front wheel and tire assembly. 3. Remove and discard the front axle wheel end nut.
^ To install, tighten to 200 Nm (148 ft. lbs.)
4. CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang
suspended from the hose.
Remove the 2 disc brake caliper guide pin bolts and position the disc brake caliper aside. ^
To install, tighten to 33 Nm (24 ft. lbs.)
^ Using mechanic's wire, position the disc brake caliper aside.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5008
5. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint
components can result.
Using the special tool, press the outboard CV joint until it is loose in the hub.
6. Remove the tie-rod nut.
^ To install, tighten to 70 Nm (52 ft. lbs.)
7. Using the special tool, separate the tie rod from the knuckle.
8. Remove the stabilizer bar link nut.
^ To install, tighten to 25 Nm (18 ft. lbs.)
9. Remove the upper ball joint nut.
^ To install, tighten to 69 Nm (51 ft. lbs.)
10. CAUTION: Do not allow the knuckle to hang freely. It is possible to overextend and internally
separate each inner CV joint from its
housing.
Using the special tool, disconnect the upper ball joint from the knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5009
11. CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the
inboard CV joint housing.
NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle.
Using the special tool, disengage the LH CV joint housing from the side gear.
12. Remove the LH halfshaft.
13. CAUTION: Do not damage the axle shaft oil seal, the machined sealing surface on the inboard
CV joint housing or the axle shaft splines.
CAUTION: Install a new retainer circlip on the outboard spline end of the axle shaft before
reseating the axle shaft in the differential side gear.
Pull the RH halfshaft and the axle shaft away from the axle tube, and separate the inboard CV joint
housing from the axle shaft.
14. Remove the RH halfshaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5010
15. CAUTION: Install a new circlip every time the halfshaft is removed.
NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the
groove to prevent the circlip from overexpanding.
To install, reverse the removal procedure.
Rear Drive Halfshafts
Halfshaft
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5011
Material
Removal and Installation
1. CAUTION: Do not loosen the rear axle wheel end nut until after the wheel and tire assembly are
removed from the vehicle. Wheel
bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. Remove the rear wheel and tire assembly. 3. Remove and discard the rear axle wheel end nut.
^ To install, tighten to 275 Nm (203 ft. lbs.)
4. CAUTION: Do not use a hammer to separate the rear axle halfshaft assembly from the hub.
Damage to the threads and internal CV
joint components can result.
Using the special tool, press the outboard CV joint until it is loose in the hub.
5. Remove the brake cable retainer screw.
^ To install, tighten to 20 Nm (15 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5012
6. Remove and discard the outboard toe link nut and back out the bolt for clearance.
^ To install, tighten to 350 Nm (259 ft. lbs.) at curb ride height.
7. Remove and discard the lower arm outboard bolt.
^ To install, tighten to 275 Nm (203 ft. lbs.) at curb ride height.
8. Remove and discard the 3 wheel knuckle bolts.
^ To install, tighten to 275 Nm (203 ft. lbs.)
9. Pivot the wheel knuckle assembly upward on the upper arm outboard bolt.
^ Loosen the upper arm bolt to prevent bushing damage. ^
To install, tighten to 275 Nm (203 ft. lbs.) at curb ride height.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5013
10. CAUTION: Do not damage the stub shaft pilot bearing oil seal or the machined sealing surface
on the inboard CV joint housing.
CAUTION: Do not allow the splines on the inboard CV joint housing to touch the stub shaft pilot
bearing oil seal.
NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle.
Using the special tool, disengage the inboard CV joint housing from the differential side gear.
11. Remove the halfshaft assembly.
12. CAUTION: Do not tighten the rear wheel hub nut with the vehicle on the ground. The nut must
be tightened to specification before the
vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded
with the weight of the vehicle applied.
CAUTION: Install and tighten the new axle wheel end nut to specification in a continuous rotation.
Stopping the rotation during installation will cause the nylon lock to seat incorrectly. This will cause
incorrect torque readings while tightening the axle wheel end nut and lead to bearing failure.
Always install a new axle wheel end nut, after loosening or when not tightened to specifications, in
a continuous rotation.
CAUTION: Always install a new differential stub shaft seal whenever the halfshaft is removed.
CAUTION: Install a new circlip every time the halfshaft is removed from the axle.
NOTE: Start one end of the circlip in the groove and work the circlip over the halfshaft and into the
groove to prevent the circlip from overexpanding.
NOTE: Apply the brake to keep the halfshaft from rotating.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5014
13. Carry out a rear wheel alignment.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5015
Axle Shaft Assembly: Overhaul
Front Drive Halfshafts
Halfshaft
Special Tool(s)
Disassembly
1. Remove the halfshaft assembly. 2. For the inboard CV joint:
1 Remove and discard the boot clamps.
2 Remove the inboard CV joint housing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5016
3. For the inboard CV joint:
1 Remove and discard the retainer circlip.
2 Slide the boot away from the CV joint.
4. Using a suitable 3-jaw puller, remove the CV joint.
5. Remove and discard the inner CV boot.
6. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or
installed from the inboard CV joint side of the
shaft.
For the outboard CV joint: 1
Remove and discard the boot clamps.
2 Remove and discard the boot.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5017
7. If necessary, press the anti-lock brake sensor indicator ring from the outer CV joint.
Assembly
1. If removed, install a new anti-lock brake sensor indicator ring on the outer CV joint.
2. Lubricate the outboard CV joint.
1 Pack the outboard CV joint with grease from the kit. ^
One-third of the grease must be installed in the joint with the remainder placed in the boot.
2 Spread the remaining grease evenly inside the boot.
3. Position the boot so the rib on the boot is located in the groove of the shaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5018
4. Position the outboard halfshaft boot and the outboard boot clamps.
1 Position the boot.
2 Position the boot clamps.
5. Install the outboard CV boot clamps.
6. Position the inboard clamp and boot.
7. Install the CV joint and snap ring on the halfshaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5019
8. Install the stop ring.
9. Fill the inboard CV joint housing with grease from the kit.
^ One-half of the grease must be installed in the joint and the remainder placed in the boot.
10. Position the CV housing on the CV joint.
11. Position the inboard halfshaft boot and clamp.
1 Position the boot in the housing groove.
2 Position the boot clamp.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5020
12. Set the halfshaft assembled length to specifications.
1 Measure the entire assembly length.
2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length.
3 Hold the inner joint to prevent the assembled length from changing, and insert a small flat-blade
screwdriver between the boot and the joint to equalize the pressure.
13. Using the special tool, install the boot clamps.
14. Install the halfshaft assembly.
Rear Drive Halfshafts
Halfshaft Joint
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5021
Special Tool(s)
Material
Disassembly
1. Remove the halfshaft assembly. 2. For the inboard CV joint:
1 Remove and discard the boot clamps.
2 Remove the inboard CV joint housing.
3. For the inboard CV joint:
1 Remove and discard the retainer circlip.
2 Slide the boot away from the CV joint.
4. Using a suitable 3-jaw puller, remove the CV joint.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5022
5. Remove and discard the tri-lobe insert and the boot.
6. NOTE: The outboard CV joint is not removable from the halfshaft. The boot must be removed or
installed from the inboard CV joint side of the
shaft.
For the outboard CV joint: 1
Remove and discard the boot clamps.
2 Remove and discard the boot.
Assembly
1. For the outboard CV joint:
1 Slide the boot on the interconnecting shaft.
2 Pack the outboard CV joint with 225 grams (7.93 oz.) of grease.
3 Spread any remaining grease evenly inside the boot.
4 Install the boot by seating it in the groove in the CV joint housing.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5023
2. Using the special tool, install the boot clamps.
3. CAUTION: Install a new circlip every time the halfshaft is removed from the axle.
CAUTION: Start one end of the circlip in the groove and work the circlip over the halfshaft and into
the groove to prevent the circlip from overexpanding.
Install a new retainer circlip.
4. Remove and discard the inboard halfshaft excluder seal, if equipped.
5. For the inboard CV joint:
1 Position the clamp on the interconnecting shaft.
2 Position the boot on the interconnecting shaft.
3 Install the tri-lobe insert.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5024
6. Using the special tool, install the CV joint.
7. Install the retainer circlip.
8. For the inboard CV joint:
1 Pack the inboard CV joint housing with 250 grams (8.82 oz.) of grease.
2 Spread any remaining grease evenly inside the boot and CV joint.
3 Install the inboard CV joint housing, seating the boot in the groove in the housing.
9. Set the halfshaft assembled length to specifications.
1 Measure the entire assembly length.
2 Push in or pull out on the inner joint as necessary to adjust the halfshaft assembled length.
3 Hold the inner joint to prevent the assembled length from changing, and insert a soft, flat tool
between the boot and the joint to equalize the pressure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Component Information > Service and Repair > Removal and Replacement > Page 5025
10. Using the special tool, install both boot clamps.
11. Install the halfshaft assembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking
Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5034
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5035
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5036
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-3 > Sep > 08
> Drivetrain - Rear Axle Seal(s) Leaking > Page 5037
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-6 > Sep > 08
> Drivetrain - Rear Axle Squealing Noise
Seals and Gaskets: Customer Interest Drivetrain - Rear Axle Squealing Noise
TSB 08-19-6
09/29/08
HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE
7/28/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or
before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at
low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle
surface.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Position vehicle on a hoist and place it in neutral.
2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM),
Section 204-04.
3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m).
(Figure 1)
CAUTION
DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM
THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT
COMPONENTS MAY RESULT.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-19-6 > Sep > 08
> Drivetrain - Rear Axle Squealing Noise > Page 5042
4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub.
(Figure 2)
5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to
lubricate the rear axle halfshaft dust seal.
6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel.
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
081906A 2006-2008 0.5 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A)
081906B 2006-2008 0.9 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1175 14
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking
Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5048
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5049
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5050
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-3
> Sep > 08 > Drivetrain - Rear Axle Seal(s) Leaking > Page 5051
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-6
> Sep > 08 > Drivetrain - Rear Axle Squealing Noise
Seals and Gaskets: All Technical Service Bulletins Drivetrain - Rear Axle Squealing Noise
TSB 08-19-6
09/29/08
HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE
7/28/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or
before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at
low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle
surface.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Position vehicle on a hoist and place it in neutral.
2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM),
Section 204-04.
3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m).
(Figure 1)
CAUTION
DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM
THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT
COMPONENTS MAY RESULT.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-19-6
> Sep > 08 > Drivetrain - Rear Axle Squealing Noise > Page 5056
4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub.
(Figure 2)
5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to
lubricate the rear axle halfshaft dust seal.
6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel.
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
081906A 2006-2008 0.5 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A)
081906B 2006-2008 0.9 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1175 14
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5057
Seals and Gaskets: By Symptom
Technical Service Bulletin # 08-19-6 Date: 080929
Drivetrain - Rear Axle Squealing Noise
TSB 08-19-6
09/29/08
HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE
7/28/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or
before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at
low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle
surface.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Position vehicle on a hoist and place it in neutral.
2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM),
Section 204-04.
3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m).
(Figure 1)
CAUTION
DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM
THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT
COMPONENTS MAY RESULT.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5058
4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub.
(Figure 2)
5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to
lubricate the rear axle halfshaft dust seal.
6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel.
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
081906A 2006-2008 0.5 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A)
081906B 2006-2008 0.9 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1175 14
Disclaimer
Technical Service Bulletin # 08-19-3 Date: 080929
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5059
Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5060
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5061
FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A
NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN
THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5062
Includes Time To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed
With A, B, Or C (Do Not Use With 4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5063
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Technical Service Bulletin # 08-19-3 Date: 080929
Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-3
09/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8
IFS, 8.8 IRS, AND 9.75 IRS AXLES
FORD: 2002-2008 Explorer 2003-2008 Expedition 2006-2008 Explorer Sport Trac
LINCOLN: 2003-2005 Aviator 2003-2008 Navigator
MERCURY: 2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer
vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD
equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped
with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the
unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle
lube leak. The majority of the vehicles with this condition will be located in northern Canada and
Alaska due to the extreme cold weather.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS
DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY
RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5064
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW
UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006
MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL
YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A
SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY
RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE.
THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft® Metal Brake Parts Cleaner or
equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite® Leak Detection Dye for Gasoline Engine
Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop
Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED
SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN
AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40
Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL
SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO
APPEAR.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5065
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of
leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the
customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS
PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE
GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY
ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED,
THERE SHOULD BE NO FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE
SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL
SEPARATE, RESULTING IN THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM),
Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle Seal Leaks. Includes Time to Add Oil Dye and Road Test. This Labor
Operation Can Be Claimed With Any Of The Labor Operations In This Article. (Do Not Use With
4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008 Explorer Sport Trac, 2002-2005 Aviator: INSPECT Axle Seal Leaks.
Includes Time to Add Oil Dye and Road Test. This Labor Operation Can Be Claimed With Any Of
The Labor Operations In This Article. (Do Not Use With 4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A,
4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5066
Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides. This Labor
Operation Can Be Claimed With A, D, Or E (Do Not Use With 4139A, 4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac :Replace Rear Axle Stub Shaft Seal. Includes Time
To Remove and Install Halfshaft. One Side. This Labor Operation Can Be Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
One Side. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. One Side. This Labor
Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A, B, Or C (Do Not Use With 4139A,
4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008 Explorer Sport Trac Replace Rear Axle Stub Shaft Seal. Includes Time To
Remove and Install Halfshaft. Both Sides. This Labor Operation Can Be
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5067
Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft.
Both Sides. This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub Shaft Seal. Includes Time To Remove and Install Halfshaft. Both Sides.
This Labor Operation Can Be Claimed With A (Do Not Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
Disclaimer
Technical Service Bulletin # 08-19-6 Date: 080929
Drivetrain - Rear Axle Squealing Noise
TSB 08-19-6
09/29/08
HIGH PITCHED SQUEAL NOISE FROM THE REAR AXLE AREA - BUILT ON OR BEFORE
7/28/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built on or
before 7/28/2008 may exhibit a high pitched squeal noise from the rear axle area while driving at
low speeds. This may be caused by the rear outer axle halfshaft dust seals contacting the knuckle
surface.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Position vehicle on a hoist and place it in neutral.
2. Remove the rear wheel and tire. For additional information, refer to Workshop Manual (WSM),
Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5068
3. Remove and discard the rear axle wheel end nut. To install, tighten to 203 lb-ft (275 N.m).
(Figure 1)
CAUTION
DO NOT USE A HAMMER TO SEPARATE THE REAR AXLE HALFSHAFT ASSEMBLY FROM
THE HUB. DAMAGE TO THE THREADS AND INTERNAL CONSTANT VELOCITY (CV) JOINT
COMPONENTS MAY RESULT.
4. Use the special tool, press the outboard constant velocity (CV) joint until it is loose in the hub.
(Figure 2)
5. Use a brush and apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound to
lubricate the rear axle halfshaft dust seal.
6. Reverse steps 2 and 3 to install halfshaft, tire, and wheel.
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
081906A 2006-2008 0.5 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate One Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.5 Hrs(Do Not Use With 4139A, 5968A)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
5069
081906B 2006-2008 0.9 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Lubricate Both Rear Constant Velocity
Outboard Joint to Knuckle Dust Seal: 0.9 Hrs (Do Not Use With 4139A, 5968A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1175 14
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove and discard the halfshaft nut and washer.
^ To install, tighten to 250 Nm (184 ft. lbs.)
3. Using the special tool, separate the outboard CV joint from the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5074
4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^
Discard the bolts.
^ Support the caliper and anchor plate assembly using mechanic's wire.
^ To install, tighten to 165 Nm (122 ft. lbs.)
5. Remove the brake disc.
6. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it
from the wheel bearing and hub.
Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel
bearing and hub assembly. ^
To install, tighten to 18 Nm (13 ft. lbs.)
7. Remove the 3 bolts and the wheel bearing and hub assembly.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 ft. lbs.)
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5075
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts.
^ To install, tighten to 8 Nm (71 inch lbs.)
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front > Page 5076
4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To
install, reverse the removal procedure. 7. Install the wheel knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Axle Nut ...............................................................................................................................................
................................................ 250 Nm (184 ft. lbs.)
Remove and discard the halfshaft nut and washer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support >
Component Information > Service and Repair
Center Support: Service and Repair
Driveshaft Center Bearing
Disassembly
NOTE: The driveshaft center bearing on driveshafts with constant velocity (CV) joint flanges are not
serviced. If the driveshaft center bearing is worn or damaged, install a new driveshaft.
1. Remove the driveshaft.
2. CAUTION: Do not clamp the driveshaft tube in a vise. Denting or localized fracturing may result
causing driveshaft failure during
vehicle operation.
Position the center universal joint yoke ears in a vise so that the C-washer is pointing up and the
front section is free to move.
3. Loosen the bolt inside the center cardan joint enough to allow the C-washer to fall from under
the bolt head.
^ To install, tighten to 37 Nm (27 ft. lbs.)
4. NOTE: Index-mark the front and rear driveshaft sections.
NOTE: The rear section has a master splined shaft and yoke.
NOTE: The bolt head will fit through the internal spline of the center cardan.
Using a rubber mallet, separate the driveshaft sections.
5. Using a suitable puller, remove the driveshaft center bearing from the rear section.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support >
Component Information > Service and Repair > Page 5085
6. NOTE: Install the new center bearing with the 3 bend tabs and dust seal lip facing the front of the
vehicle.
To install, reverse the removal process.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front
Drive/Propeller Shaft: Service and Repair Driveshaft - Front
Driveshaft - Front
Material
Removal and Installation
CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight
of the driveshaft can pinch the boot between the driveshaft and the constant velocity (CV) joint
flange which can cause the boot to tear.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Index-mark the front driveshaft to maintain driveshaft balance.
3. Remove and discard the 6 CV joint bolts and CV joint washers.
^ To install, tighten to 30 Nm (22 ft. lbs.)
4. Remove the 4 universal joint strap bolts and remove the universal joint straps.
^ Discard the bolts.
^ To install, tighten to 19 Nm (14 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5090
5. Remove the front driveshaft.
6. CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the
factory. When housed correctly, the can
will appear as shown in the cut-away illustration (top box). Do not reseat the can in the CV joint
housing if the can's flange is above the CV joint housing as shown in the cut-away illustration
(bottom box). Install a new driveshaft.
CAUTION: Vehicles built after January 6, 2006 are equipped with a control vent on the can of the
CV joint housing. This vent is shown in the center of the illustrated can. If this vent is damaged, a
new driveshaft must be installed.
CAUTION: Tighten the CV joint bolts evenly in a cross pattern or damage will occur to the CV joint.
NOTE: Install new CV joint washers and CV joint bolts. If new CV joint bolts are not available, coat
the threads of the original CV joint bolts with Threadlock and sealer.
NOTE: Install new universal joint strap bolts. If new universal joint strap bolts are not available, coat
the threads of the original universal joint strap bolts with Threadlock and sealer.
NOTE: The CV joint is not serviceable. Install a new driveshaft if damaged.
NOTE: Verify that the universal joint bearing caps are seated in the pinion yoke flange before
tightening the universal joint strap bolts.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5091
Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, One-Piece, Four Wheel Drive (4WD)
Driveshaft - Rear, One-Piece, Four Wheel Drive (4WD)
Material
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. If equipped, remove the skid plate. 3. Index-mark the
driveshaft flange to the transfer case rear output flange to maintain driveshaft balance.
4. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance.
5. Remove and discard the driveshaft flange bolts.
^ To install, tighten to 112 Nm (83 ft. lbs.)
6. Remove and discard the transfer case rear output flange bolts.
^ To install, tighten to 112 Nm (83 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5092
7. CAUTION: The driveshaft flange fits tightly on the axle pinion flange pilot and the transfer case
output flange. Never hammer on the
driveshaft, or any of its components, to disconnect the driveshaft flanges from the mating flanges.
Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flanges.
Using a suitable tool as shown, disconnect the driveshaft flanges and remove the driveshaft.
8. CAUTION: The driveshaft flanges fit tightly on the pinion flange pilots. To make sure that the
driveshaft flanges seat squarely on the
pinion flanges, tighten the driveshaft flange bolts evenly in a cross pattern.
CAUTION: If new driveshaft flange bolts are not available, coat the threads of the original
driveshaft flange bolts with Threadlock and sealer.
To install, reverse the removal procedure. ^
Install new fasteners.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5093
Drive/Propeller Shaft: Service and Repair Driveshaft - Rear, Two-Piece, Four Wheel Drive (4WD)
Driveshaft - Rear, Two-Piece, Four Wheel Drive (4WD)
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the nuts from the driveshaft center bearing bracket.
^ To install, tighten to 55 Nm (41 ft. lbs.)
3. Index-mark the constant velocity (CV) joint to the transfer case output flange.
4. Index-mark the rear universal joint flange to the differential pinion flange.
5. Remove and discard the 6 CV joint bolts.
^ To install, tighten to 30 Nm (22 ft. lbs.)
6. Remove and discard the 4 driveshaft flange bolts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5094
^ To install, tighten to 112 Nm (83 ft. lbs.)
7. NOTE: Never hammer on the driveshaft, or any of its components, to disconnect the driveshaft
flange from the differential pinion flange.
Using a suitable tool, pry only in the area shown to separate the driveshaft flange and the
differential pinion flange.
8. Slide the driveshaft toward the rear of the vehicle, while maneuvering the front section over the
top of the vehicle frame crossmember. 9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5095
Drive/Propeller Shaft: Service and Repair Driveshaft Slip Yoke Boot
Driveshaft Slip Yoke Boot
Special Tool(s)
Material
Removal
1. Remove the driveshaft. 2. Index-mark the driveshaft on both sides of the driveshaft slip yoke
boot.
3. Remove and discard the driveshaft slip yoke boot clamps. 4. Separate the driveshaft. Remove
the driveshaft slip yoke boot.
Installation
1. NOTE: Grease both ends of the driveshaft.
Position the driveshaft slip yoke boot and the driveshaft slip yoke boot clamps on one end of the
driveshaft.
2. Align the index marks and connect the driveshaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft - Front > Page 5096
3. Using the special tool, install the new driveshaft slip yoke boot.
4. Install the driveshaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 - Snap Ring Type
Universal Joint: Service and Repair Driveshaft Universal Joint - Snap Ring Type
Driveshaft Universal Joint - Snap Ring Type
Special Tool(s)
Disassembly and Assembly
NOTE: The front driveshaft constant velocity (CV) joint is not repairable.
1. Remove the driveshaft. 2. Index-mark the components at the universal joints for reassembly. 3.
Remove and discard the 4 snap rings. 4. Position the driveshaft in the special tool. Using the
special tool, press out a bearing cup.
5. If necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way
out. 6. Rotate the driveshaft and press on the spider to remove the remaining bearing cup. 7.
Remove the driveshaft flange. 8. Position the driveshaft in the special tool. Using the special tool,
press out the bearing cup.
9. If necessary, use a pair of pliers to remove the bearing cup if it cannot be pressed all the way
out.
10. Rotate the driveshaft and press on the spider to remove the remaining bearing cup. 11.
Remove the spider.
12. NOTE: Clean the bearing cup bores.
NOTE: Check the universal joints for freedom of movement. If binding, strike the driveshaft flange
with a brass or plastic hammer. Do not strike the universal joint.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 - Snap Ring Type > Page
5101
To assemble, reverse the disassembly procedure. ^
Use the yellow snap rings supplied in the kit to install the universal joint. If difficulty is encountered
with the yellow snap rings, install the black snap rings, as required.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 - Snap Ring Type > Page
5102
Universal Joint: Service and Repair Driveshaft Universal Joint - Stake Type
Driveshaft Universal Joint - Stake Type
1. The staked driveshaft universal joints are not serviced separately within the warranty period.
Install a new driveshaft if worn or damaged. 2. Universal joint service kits with instructions are
available through a Ford authorized dealer for a high mileage repair.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flex plate bolts
................................................................................................................................................... 80
Nm (59 ft. lbs.) in the sequence shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5106
Flex Plate: Diagrams
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
5107
Flex Plate: Service and Repair
Flexplate
Removal and Installation
1. Remove the transmission. 2. Remove the 6 bolts and the flexplate.
^ To install, tighten to 80 Nm (59 ft. lbs.) in the sequence shown.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Diagrams
Flywheel: Diagrams
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams
C2260
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information >
Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements
Manual Transmission/Transaxle: Technical Service Bulletins Vehicle - Tow Capability/Service Kit
Requirements
TSB 06-7-1
04/17/06
NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS
FORD: 2004-2006 Focus 2004 F-150 Heritage 2004-2005 Explorer Sport Trac 2004-2006 Escape,
Explorer, F-150-350 Series, Ranger 2005-2006 Escape Hybrid 2007 Explorer Sport Trac
LINCOLN: 2006 Mark LT
MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 06-4-5 to update the vehicle neutral tow application chart.
ISSUE Various vehicles are neutral tow capable. Refer to the following chart to determine neutral
tow capability for specific vehicle applications, and to determine if a Service Kit is required to make
the vehicle neutral tow capable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information >
Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements > Page 5124
ACTION Review the neutral tow application chart (Figure 1) and order the kit, if applicable.
Reprogramming of various modules may be required for some installations. Installation instructions
are included with the kit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information >
Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements > Page 5125
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and
Operation
Power Take-Off: Description and Operation
POWER TAKE-OFF (PTO) SWITCH AND CIRCUITS
The PTO circuit is used by the PCM to disable some of the on board diagnostics (OBD) monitors
during PTO operation. The PTO switch is normally open. When the PTO unit is activated, the PTO
switch is closed and battery voltage is supplied to the PTO input circuit. This indicates to the PCM
that an additional load is being applied to the engine. The PTO indicator lamp illuminates when the
PTO system is functioning correctly and flashes when the PTO system is damaged
When the PTO unit is activated, the PCM disables some OBD monitors, which may not function
reliably during PTO operation. Without the PTO circuit information to the PCM, false DTCs may be
set during PTO operation. Prior to an Inspection/Maintenance test, operate the vehicle with the
PTO disengaged long enough to successfully complete the OBD Monitors.
PTO Circuits Description
The 3 PTO input circuits are PTO mode, PTO engage, and PTO RPM.
The PTO engage circuit is used when the operator is requesting the PCM to check the needed
inputs required to initiate the PTO engagement.
The PTO RPM circuit is used for the operator to request additional engine RPM for PTO operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: Customer Interest Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page 5139
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5144
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
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c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
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Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
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Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM > Page 5146
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
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Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues
Control Module: All Technical Service Bulletins Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
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Bulletins for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various Driveability Issues > Page 5152
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
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Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
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a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
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c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
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8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
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Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations
View 151-9 (Automatic Transmission)
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Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 5164
Control Module: Diagrams
C281A
C281B
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Control Module: Service and Repair
Four Wheel Drive (4WD) Control Module
Four Wheel Drive (4WD) Control Module
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Open the
glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4.
Disconnect the electrical connectors. 5. Remove the four wheel drive (4WD) control module. 6. To
install, reverse the removal procedure.
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Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
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Brake Switch - TCC: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Page 5172
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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Page 5173
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Page 5174
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Page 5175
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Symbols Part 2
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Page 5177
Symbols Part 3
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Symbols Part 4
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Page 5179
Symbols Part 5
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Page 5180
Brake Switch - TCC: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Page 5182
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Page 5183
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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Page 5184
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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Page 5185
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
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Page 5187
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The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Overdrive Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5194
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5195
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5196
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5197
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5198
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5199
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5200
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5201
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5202
Overdrive Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5203
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5204
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5205
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5206
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5207
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5208
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5209
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5210
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions
Throttle Position Sensor/Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5215
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5216
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5217
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5218
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5219
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5220
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5221
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5222
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5223
Throttle Position Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5224
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5225
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5226
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5227
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5228
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5229
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5230
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5231
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions
Transmission Mode Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5236
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5237
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5238
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5239
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5240
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5241
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5242
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5243
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5244
Transmission Mode Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5245
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5246
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5247
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5248
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5249
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5250
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5251
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and
Instructions > Page 5252
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation >
Transmission Control (TC) Switch
Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch
Transmission Control (TC) Switch
The transmission control (TC) switch is a momentary contact switch located on the selector lever
knob. Pushing the TC switch will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the
instrument panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation >
Transmission Control (TC) Switch > Page 5255
Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS)
TRANSMISSION CONTROL SWITCH (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5256
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Removal
1. Remove the transmission selector lever knob.
2. Remove the transmission control switch from the knob.
Installation
1. Install the transmission control switch into the knob.
2. Install the transmission selector lever knob.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5261
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5262
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5263
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5264
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5265
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5266
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5267
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5268
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5269
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5270
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5271
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5272
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5273
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5274
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5275
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5276
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5277
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5278
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5283
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5284
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5285
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5286
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5287
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5288
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5289
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5290
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5291
Transmission Speed Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5292
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5293
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5294
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5295
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5296
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5297
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5298
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5299
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5300
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5301
C164
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5306
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5307
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5308
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5309
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5310
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5311
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5312
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5313
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5314
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5315
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5316
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5317
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5318
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5319
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5320
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5321
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5322
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5327
C284
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5328
Four Wheel Drive Selector Switch: Service and Repair
Mode Select Switch (MSS)
Mode Select Switch (MSS)
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
bezel. 3. With the center console cover open, remove the floor console center finish panel screws.
4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical
connector. 5. Remove the floor console center finish panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5329
6. Disconnect the electrical connector(s). Disengage the locking tangs and remove the mode select
switch (MSS) from the instrument panel center
finish panel.
7. To install, reverse the removal procedure.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Service and Repair
Transfer Case Actuator: Service and Repair
Transfer Case Shift Motor
Material
Removal and Installation
1. With the ignition ON, press the 4x4 HIGH button on the mode select switch (MSS). 2. With the
transmission in the NEUTRAL position, raise and support the vehicle. For additional information,
refer to Maintenance/Service and
Repair.
3. Disconnect the transfer case shift motor harness connector.
4. Remove the bracket bolt and transfer case shift motor mounting bolts and remove the transfer
case shift motor.
5. To install, reverse the removal procedure.
^ Apply a coat of Multi-Purpose Grease to the transfer case shift motor bolts.
^ Tighten to 10 Nm (89 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Locations
View 151-9 (Automatic Transmission)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Locations > Page 5338
Control Module: Diagrams
C281A
C281B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Locations > Page 5339
Control Module: Service and Repair
Four Wheel Drive (4WD) Control Module
Four Wheel Drive (4WD) Control Module
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Open the
glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4.
Disconnect the electrical connectors. 5. Remove the four wheel drive (4WD) control module. 6. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Case Capacity .......................................................................................................................
.................................................................... 1.5 Quarts
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications > Page 5344
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Page 5345
Fluid - Transfer Case: Service and Repair
Transfer Case Draining and Filling
Material
1. CAUTION: Transfer case failure can result if the correct fill procedures are not followed.
Remove the drain plug and drain the fluid. ^
Position a suitable drain pan under the transmission.
2. Clean and install the drain plug.
^ To install, tighten to 20 Nm (15 ft. lbs.)
3. CAUTION: Incorrect fluid fill can result in transfer case failure.
NOTE: Fill the transfer case with the vehicle on a level surface.
NOTE: The fluid level should be just below the fill plug.
NOTE: Clean the area around the fill plug.
Remove the fill plug. Using a suitable oil suction gun, fill the transfer case to the correct level with
the specified fluid. ^
The fluid must be just below the fill plug hole. Because the fluid can be reached with a finger does
not mean the fluid is at the correct level. Make sure the fluid is level with the filler opening for the
correct fluid level.
4. Clean and install the fill plug.
^ To install, tighten to 15 Nm (11 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Diagrams
C2260
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5352
C284
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5353
Four Wheel Drive Selector Switch: Service and Repair
Mode Select Switch (MSS)
Mode Select Switch (MSS)
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
bezel. 3. With the center console cover open, remove the floor console center finish panel screws.
4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical
connector. 5. Remove the floor console center finish panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5354
6. Disconnect the electrical connector(s). Disengage the locking tangs and remove the mode select
switch (MSS) from the instrument panel center
finish panel.
7. To install, reverse the removal procedure.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four
Wheel Drive Indicator Lamp > Component Information > Diagrams
C2260
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Locations
View 151-9 (Automatic Transmission)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Locations > Page 5363
Control Module: Diagrams
C281A
C281B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Locations > Page 5364
Control Module: Service and Repair
Four Wheel Drive (4WD) Control Module
Four Wheel Drive (4WD) Control Module
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Open the
glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4.
Disconnect the electrical connectors. 5. Remove the four wheel drive (4WD) control module. 6. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair
Seals and Gaskets: Service and Repair
Transfer Case Rear Output Shaft Seal
Special Tool(s)
Material
Removal and Installation
1. With the transmission in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Index-mark the rear output flange and the driveshaft yoke.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair > Page 5368
3. CAUTION: If new driveshaft yoke bolts are not available, coat the threads of the original bolts
with Threadlock and sealer.
Remove the 4 driveshaft yoke bolts. ^
To install, tighten to 112 Nm (83 ft. lbs.) evenly in a cross pattern.
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 flange from the pinion flange. Pry only in the area shown,
with a suitable tool, to disconnect the driveshaft flange from the pinion flange.
Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle pinion flange.
5. Position the driveshaft aside and support with mechanic's wire.
6. Using the special tool to hold the output flange, remove the nut.
^ To install, tighten to 355 Nm (262 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair > Page 5369
7. Remove the output shaft yoke washer. 8. Using the special tool, remove the rear output shaft
flange.
9. Remove and discard the rear output shaft flange oil seal.
10. Using the special tools, remove the rear output shaft oil seal.
11. Using the special tool, install a new rear output shaft oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair > Page 5370
12. To install, reverse the removal procedure.
^ Always install a new rear output shaft flange oil seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations > Page 5375
C284
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations > Page 5376
Four Wheel Drive Selector Switch: Service and Repair
Mode Select Switch (MSS)
Mode Select Switch (MSS)
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
bezel. 3. With the center console cover open, remove the floor console center finish panel screws.
4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical
connector. 5. Remove the floor console center finish panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations > Page 5377
6. Disconnect the electrical connector(s). Disengage the locking tangs and remove the mode select
switch (MSS) from the instrument panel center
finish panel.
7. To install, reverse the removal procedure.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Service and Repair
Transfer Case Actuator: Service and Repair
Transfer Case Shift Motor
Material
Removal and Installation
1. With the ignition ON, press the 4x4 HIGH button on the mode select switch (MSS). 2. With the
transmission in the NEUTRAL position, raise and support the vehicle. For additional information,
refer to Maintenance/Service and
Repair.
3. Disconnect the transfer case shift motor harness connector.
4. Remove the bracket bolt and transfer case shift motor mounting bolts and remove the transfer
case shift motor.
5. To install, reverse the removal procedure.
^ Apply a coat of Multi-Purpose Grease to the transfer case shift motor bolts.
^ Tighten to 10 Nm (89 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5388
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5389
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5390
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5391
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5392
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5393
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5394
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5395
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5396
Pressure Regulating Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5397
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5398
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5399
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5400
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5401
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5402
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5403
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5404
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair
Shift Interlock Solenoid: Service and Repair
Brake Shift Interlock Actuator
Brake Shift Interlock Actuator
Removal
1. Remove the front floor console. For additional information, refer to Console. 2. Disconnect the
brake shift lock actuator electrical connector.
3. Remove the screw and the brake shift lock actuator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service
and Repair > Page 5408
Installation
1. Install the brake shift lock actuator.
2. Connect the brake shift lock actuator electrical connector.
3. Install the front floor console. For additional information, refer to Console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5413
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5414
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5415
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5416
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5417
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5418
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5419
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5420
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5421
Shift Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5422
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5423
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5424
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5425
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5426
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5427
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5428
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5429
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5434
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5435
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5436
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5437
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5438
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5439
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5440
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5441
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5442
Torque Converter Clutch Solenoid: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5443
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5444
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5445
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5446
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5447
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5448
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5449
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5450
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Service and Repair
Transfer Case Actuator: Service and Repair
Transfer Case Shift Motor
Material
Removal and Installation
1. With the ignition ON, press the 4x4 HIGH button on the mode select switch (MSS). 2. With the
transmission in the NEUTRAL position, raise and support the vehicle. For additional information,
refer to Maintenance/Service and
Repair.
3. Disconnect the transfer case shift motor harness connector.
4. Remove the bracket bolt and transfer case shift motor mounting bolts and remove the transfer
case shift motor.
5. To install, reverse the removal procedure.
^ Apply a coat of Multi-Purpose Grease to the transfer case shift motor bolts.
^ Tighten to 10 Nm (89 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Diagrams
C2260
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various
Driveability Issues
Control Module: Customer Interest Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control - Various
Driveability Issues > Page 5474
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set
In TCM
Control Module: Customer Interest A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set
In TCM > Page 5479
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set
In TCM > Page 5480
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp' ON/Multiple DTC's Set
In TCM > Page 5481
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control Various Driveability Issues
Control Module: All Technical Service Bulletins Engine, A/T Control - Various Driveability Issues
TSB 07-10-12
05/28/07
VARIOUS DRIVEABILITY AND AC PERFORMANCE QUALITY SYMPTOMS - 4.6L 3V 6R60
EQUIPPED VEHICLES ONLY
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
This article supersedes TSB 06-23-11 and 07-2-8 to update the Service Procedure.
ISSUE Some 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles equipped
with the 4.6L engine and 6R60 transmission may exhibit various driveability and A/C performance
quality symptoms.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Apply reprogram to 2006-2007 Explorer/Mountaineer and 2007 Explorer Sport Trac vehicles that
may exhibit the following symptoms:
SYMPTOMS
^ Cold hesitation/surge
^ Long crank
^ Engine fan noise on cold start and A/C operation
^ High idle during warm up (cold engine)
^ Inaccurate Message Center average fuel economy estimation
^ Overheat indication at idle in gear in high ambient temperatures
^ A/C shutoff at idle in gear in high ambient temperatures
^ Lower than desired RPM during long deceleration
1. Install IDS or equivalent and ID the vehicle.
2. Update the PCM and 1CM calibration using IDS release 48.13 and higher or 49.2 and higher.
This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained
at the website. Since the TCM cannot be reprogrammed alone, reprogram the PCM/TCM together
to ensure that both engine and transmission calibrations are updated to the latest level
simultaneously.
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
071012A 2006-2007 0.6 Hr.
Explorer/Mountaineer, And 2007 Explorer Sport Trac 4.6L Engine, 6R60 Transmission: Reprogram
PCM And TCM (Do Not
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 07-10-12 > May > 07 > Engine, A/T Control Various Driveability Issues > Page 5487
Use With 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
RECAL 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp'
ON/Multiple DTC's Set In TCM
Control Module: All Technical Service Bulletins A/T - 'Wrench Lamp' ON/Multiple DTC's Set In TCM
TSB 07-6-3
04/02/07
6R60/75 - DTC-MECHATRONIC ASSEMBLY / POSSIBLE WRENCH LIGHT ON
FORD: 2006-2007 Explorer 2007 Expedition, Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer and Mountaineer, 2007 Sport Trac, and 2007 Expedition
vehicles may exhibit the following diagnostic trouble codes in the transmission control module
(1CM) memory with or without the wrench light on. The codes include the following; P0658, P0657,
P0972, P0973, P0974, P0975, P0976, P0977, P0978, P0979, P0980, P0981, P0982, P0083,
P0961, P0962, P0963, P2763, P2764, P0985, P0986, P0711, P0712. The cause is contamination
at the mechatronic assembly.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
IF THE MECHATRONIC ASSEMBLY WAS BUILT WITH A FOAM BARRIER STRIP, REMOVE
AND DISCARD, REMOVE ANY SOURCES OF CONTAMINATION, AND INSTALL A NEW FOAM
BARRIER STRIP.
SERVICE PROCEDURE
Remove the source of contamination from the transmission control unit (TCU)/solenoid connections
and/or at the transmission fluid temperature (TFT) window. Install the foam barrier strip to prevent
recurrence.
1. Remove mechatronic assembly using the Workshop Manual (WSM), Section 307-01.
2. Remove the six (6) long fasteners from the TCM unit. (Figure 1)
3. Carefully separate the TCM from the mechatronic assembly. Do not separate the two halves of
the main control during this procedure.
NOTE
IF THE WRENCH LIGHT IS NOT ILLUMINATED THE CONTAMINATION MAY BE DISLODGED
FROM THE TCU/SOLENOID CONNECTORS AND FLOATING WITHIN THE HYDRAULICS
SYSTEM.
4. Inspect the TCM at the following locations for metal chips or other metallic contamination.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp'
ON/Multiple DTC's Set In TCM > Page 5492
a. Closely inspect both sides of the TCU blades for machining chips or metallic contamination.
(Figure 2)
b. Closely inspect all solenoid terminals for machining chips and or metallic contamination. (Figure
3 and 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp'
ON/Multiple DTC's Set In TCM > Page 5493
c. Closely inspect the TFT window for any machining chips and or metallic contamination. (Figure
5)
5. Prior to installation of the protective strip, remove all machining chips and or other metallic
contamination from these areas with a clean, lint free cloth.
6. Install the new foam barrier strip over the blades of the TCU, no special barrier strip is required
for the TFT. (Figure 2 shows before foam barrier strip is installed, Figure 6 shows after the foam
barrier strip is installed).
7. Reinstall the TCU on to the main control. Install the six (6) long bolts into the TCM unit. Tighten
to 53 lb-in (6 N.m). (Figure 7) Reinstall/verify the cooler bypass valve (spring end into the case first,
"point" down), reinstall pump seal adaptor, and four (4) center support seals following WSM,
Section 307-01.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 07-6-3 > Apr > 07 > A/T - 'Wrench Lamp'
ON/Multiple DTC's Set In TCM > Page 5494
8. Reinstall the mechatronic assembly following the WSM, Section 307-01.
9. Install a new fluid filter, and reusable gasket following WSM, Section 307-01.
10. Set the transmission fluid level following the WSM, Section 307-01.
11. Clear all DTC(s) from the TCM.
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
070603A 2006-2007 2.6 Hrs.
Explorer/Mountaineer, 2007 Explorer Sport Trac 6R60 Transmission: Check DTCs, Install New
Barrier Protective Strip, Includes Time To Remove And Install Mechatronic/TCM, Set Transmission
Fluid, And Reprogram The TCM (Do Not Use With 7191A, 7191A1, 12650D, 12650D84)
070603A 2007 Expedition 6R75 2.7 Hrs.
Transmission: Check DTCs, Install New Barrier Protective Strip, Includes Time To Remove And
Install Mechatronic/TCM, Set Transmission Fluid, And Reprogram The TCM (Do Not Use With
7191A, 7191A1, 12650D, 12650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B167 49
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Locations
View 151-9 (Automatic Transmission)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Locations > Page 5499
Control Module: Diagrams
C281A
C281B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Locations > Page 5500
Control Module: Service and Repair
Four Wheel Drive (4WD) Control Module
Four Wheel Drive (4WD) Control Module
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Open the
glove compartment, press in on sides and lower it to gain access. 3. Remove the 2 screws. 4.
Disconnect the electrical connectors. 5. Remove the four wheel drive (4WD) control module. 6. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions
Brake Switch - TCC: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5507
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5508
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5509
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5510
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5511
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5512
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5513
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5514
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5515
Brake Switch - TCC: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5516
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5517
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5518
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5519
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5520
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5521
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5522
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Diagram Information and Instructions > Page 5523
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams >
Page 5524
Brake Switch - TCC: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Overdrive Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5529
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5530
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5531
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5532
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5533
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5534
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5535
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5536
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5537
Overdrive Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5538
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5539
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5540
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5541
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5542
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5543
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5544
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5545
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions
Throttle Position Sensor/Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5550
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5551
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5552
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5553
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5554
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5555
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5556
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5557
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5558
Throttle Position Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5559
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5560
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5561
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5562
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5563
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5564
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5565
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5566
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions
Transmission Mode Switch: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5571
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5572
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5573
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5574
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5575
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5576
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5577
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5578
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5579
Transmission Mode Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5580
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5581
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5582
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5583
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5584
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5585
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5586
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 > Diagram Information and Instructions > Page 5587
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation > Transmission Control (TC) Switch
Transmission Mode Switch: Description and Operation Transmission Control (TC) Switch
Transmission Control (TC) Switch
The transmission control (TC) switch is a momentary contact switch located on the selector lever
knob. Pushing the TC switch will either disengage or engage the overdrive function of the
transmission. If OVERDRIVE is disengaged, the message O/D OFF will illuminate on the
instrument panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation > Transmission Control (TC) Switch > Page 5590
Transmission Mode Switch: Description and Operation Transmission Control Switch (TCS)
TRANSMISSION CONTROL SWITCH (TCS)
Typical Transmission Control Switch (TCS)
Typical Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage
overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5591
Transmission Mode Switch: Service and Repair
Transmission Control (TC) Switch
Removal
1. Remove the transmission selector lever knob.
2. Remove the transmission control switch from the knob.
Installation
1. Install the transmission control switch into the knob.
2. Install the transmission selector lever knob.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5596
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5597
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5598
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5599
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5600
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5601
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5602
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5603
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5604
Transmission Position Switch/Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5605
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5606
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5607
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5608
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5609
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5610
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5611
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5612
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5613
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5618
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5619
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5620
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5621
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5622
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5623
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5624
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5625
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5626
Transmission Speed Sensor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5627
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5628
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5629
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5630
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5631
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5632
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5633
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5634
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5635
Transmission Speed Sensor: Connector Views
C193
C143
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5636
C164
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5641
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5642
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5643
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5644
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5645
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5646
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5647
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5648
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5649
Transmission Temperature Sensor/Switch: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5650
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5651
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5652
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5653
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5654
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5655
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5656
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 5657
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5662
C284
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5663
Four Wheel Drive Selector Switch: Service and Repair
Mode Select Switch (MSS)
Mode Select Switch (MSS)
Removal and Installation
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
bezel. 3. With the center console cover open, remove the floor console center finish panel screws.
4. Raise the floor console center finish panel and disconnect the auxiliary power point electrical
connector. 5. Remove the floor console center finish panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations > Page 5664
6. Disconnect the electrical connector(s). Disengage the locking tangs and remove the mode select
switch (MSS) from the instrument panel center
finish panel.
7. To install, reverse the removal procedure.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations
View 151-15 (Center Console)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations > Page 5670
C3073
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations > Page 5671
ABS Sensor Block: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Component Information > Locations > Page 5672
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 06-6-9 > Apr > 06 >
ABS/TCS/RCS - Warning Lamp ON/DTC C1440 Set
Electronic Brake Control Module: Customer Interest ABS/TCS/RCS - Warning Lamp ON/DTC
C1440 Set
TSB 06-6-9
04/03/06
ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL
INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Sport Trac vehicles built through
3/16/2006 may exhibit an anti-lock brake system / traction control / roll stability control (ABS / TC /
RSC light) warning lamp illuminated with diagnostic trouble code C1440 pressure transducer main /
primary signal faulted. This may be caused by the integrated control unit (ICU).
ACTION Follow the Service Procedure to determine if the ABS module needs to be replaced.
NOTE
THE BASE BRAKE SYSTEM CONTINUES TO FUNCTION PROPERLY.
SERVICE PROCEDURE
1. Install scan tool, retrieve DTCs and record.
a. If DTC C1440 is retrieved, proceed to Step 2.
b. If DTC C1440 is not retrieved, this TSB does not apply. Proceed with normal diagnostics.
2. Replace the ABS module (2C219). Refer to Workshop Manual, Section 206-09 for Removal and
Installation procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-6-9 > Apr >
06 > ABS/TCS/RCS - Warning Lamp ON/DTC C1440 Set
Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS/RCS - Warning Lamp
ON/DTC C1440 Set
TSB 06-6-9
04/03/06
ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL
INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Sport Trac vehicles built through
3/16/2006 may exhibit an anti-lock brake system / traction control / roll stability control (ABS / TC /
RSC light) warning lamp illuminated with diagnostic trouble code C1440 pressure transducer main /
primary signal faulted. This may be caused by the integrated control unit (ICU).
ACTION Follow the Service Procedure to determine if the ABS module needs to be replaced.
NOTE
THE BASE BRAKE SYSTEM CONTINUES TO FUNCTION PROPERLY.
SERVICE PROCEDURE
1. Install scan tool, retrieve DTCs and record.
a. If DTC C1440 is retrieved, proceed to Step 2.
b. If DTC C1440 is not retrieved, this TSB does not apply. Proceed with normal diagnostics.
2. Replace the ABS module (2C219). Refer to Workshop Manual, Section 206-09 for Removal and
Installation procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake
Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake
Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 5691
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake
Control Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 5697
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 5698
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 5699
C155
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 5700
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Material
Removal and Installation
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
CAUTION: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and
calibrated. Follow the scan tool directions for the calibration procedures. For module configuration,
refer to Information Bus.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Page 5701
1. Remove the hydraulic control unit (HCU).
2. CAUTION: Make sure that the ABS module is properly seated to the HCU and that the torque of
the ABS module screws is correct, or
damage to the components can occur.
Remove the 4 screws and the ABS module. ^
To install, tighten to 2 Nm (18 inch lbs.).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures
Hydraulic Control Assembly - Antilock Brakes: Procedures
Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is
required only when a new HCU is installed.
1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure
to bleed the system. Begin at the RH rear caliper.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures > Page 5706
Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement
Hydraulic Control Unit (HCU)
Material
Removal and Installation
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative. Failure to follow these instructions may
result in personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Procedures > Page 5707
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the battery tray. 3. Disconnect the anti-lock brake
system (ABS) module electrical connector.
4. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 2 brake tube-to-hydraulic control unit (HCU) fittings and position the brake tubes
aside. ^
To install, tighten to 23 Nm (17 ft. lbs.).
5. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 4 brake tube-to-HCU extension tube fittings. ^
To install, tighten to 18 Nm (13 ft. lbs.).
6. Remove the 3 HCU bracket-to-frame nuts.
^ To install, tighten to 23 Nm (17 ft. lbs.).
7. Remove the HCU assembly.
8. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 4 HCU extension tube-to-HCU fittings. ^
To install, tighten to 18 Nm (13 ft. lbs.).
9. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer
assembly.
^ To install, tighten to 9 Nm (80 inch lbs.).
10. Remove the bracket-to-HCU bolts and the HCU bracket.
^ To install, tighten to 9 Nm (80 inch lbs.).
11. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Accelerometer > Component Information > Service and Repair > Page 5711
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Steering Wheel Rotation Sensor
Removal and Installation
1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2.
Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor
electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install,
reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 5718
C280
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 5719
Traction Control Switch: Service and Repair
Stability/Traction Control Switch
Removal and Installation
1. Remove the 2 floor console center finish panel screws and the floor console center finish panel.
^ To install, tighten to 9 Nm (80 inch lbs.).
2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the
instrument panel center finish panel away from the instrument panel. 5. Disconnect the stability
traction control switch electrical connector and remove the stability traction control switch from the
instrument panel
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Locations > Page 5720
center finish panel.
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 5725
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front
C150
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 5728
C440
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 5729
C160
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Left Front > Page 5730
C426
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front
Wheel Speed Sensor - Front
Wheel Speed Sensor - Front
Removal and Installation
1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3.
Remove the wheel speed sensor harness bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 5733
4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor
bolt.
^ To install, tighten to 17 Nm (13 ft. lbs.).
6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 5734
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Disconnect the wheel speed sensor electrical connector. 3.
Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt
and the wheel speed sensor.
^ To install, tighten to 8 Nm (71 inch lbs.).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Service and Repair
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component Information > Service and Repair > Page 5738
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Customer Interest: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > Customer Interest: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5747
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > By Symptom: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > By Symptom: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5753
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Technical Service Bulletins: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5759
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel
Clearcoat Cracking
Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel
Clearcoat Cracking > Page 5765
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
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise
At Low Speeds
Wheels: All Technical Service Bulletins Wheels/Tires - Popping/Snapping Noise At Low Speeds
TSB 09-11-2
06/15/09
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEED BELOW 10 MPH (16 KM/H)
FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer
LINCOLN: 2007-2008 MKX
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 09-4-3 to update the vehicle model years.
ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008
and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels
may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at
speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that
attaches to the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual
(WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise
At Low Speeds > Page 5770
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft(R) Silicone Spray
Lubricant with an extension nozzle. (Figures 1 and 2)
4. Clean any excess lubricant off the wheel with a soft cloth.
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
091102A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace One Wheel
and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091102B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace Two
Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091102C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise
At Low Speeds > Page 5771
MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire
Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
091102D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive,
Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From
Wheels When Turning
Wheels: All Technical Service Bulletins Wheels/Tires - Popping Noise From Wheels When Turning
TSB 07-23-4
11/26/07
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEEDS BELOW 10 MPH (16KM/H)
FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 07-19-6 to update the vehicle lines.
ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to
8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may
exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds
lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to
the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel
and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From
Wheels When Turning > Page 5776
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension
nozzle. (Figures 1 and 2)
NOTE
NEW WHEELS WILL NOT REQUIRE LUBRICATION.
4. Clean any excess lubricate off the wheel with a soft cloth.
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
072304A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining
Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance
Wheel Assembly (Do Not Use With 1007A, 1007A1)
072304B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two
Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
072304C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From
Wheels When Turning > Page 5777
Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS,
Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
072304D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking
Wheels: All Technical Service Bulletins Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking
TSB 07-12-2
06/25/07
16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch
wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like
spider webs.
ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection.
SERVICE PROCEDURE
Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to
Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of
affected wheel in Figure 1.
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
071202A 2006-2007 Explorer, 2007 0.5 Hr.
Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking > Page 5782
071202B 2006-2007 Explorer, 2007 0.7 Hr.
Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202C 2006-2007 Explorer, 2007 1.0 Hr.
Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202D 2006-2007 Explorer, 2007 1.2 Hrs.
Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel
Clearcoat Cracking > Page 5788
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
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise
At Low Speeds > Page 5793
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft(R) Silicone Spray
Lubricant with an extension nozzle. (Figures 1 and 2)
4. Clean any excess lubricant off the wheel with a soft cloth.
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
091102A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace One Wheel
and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091102B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace Two
Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091102C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise
At Low Speeds > Page 5794
MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire
Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
091102D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive,
Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From
Wheels When Turning > Page 5799
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension
nozzle. (Figures 1 and 2)
NOTE
NEW WHEELS WILL NOT REQUIRE LUBRICATION.
4. Clean any excess lubricate off the wheel with a soft cloth.
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
072304A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining
Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance
Wheel Assembly (Do Not Use With 1007A, 1007A1)
072304B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two
Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
072304C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From
Wheels When Turning > Page 5800
Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS,
Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
072304D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking > Page 5805
071202B 2006-2007 Explorer, 2007 0.7 Hr.
Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202C 2006-2007 Explorer, 2007 1.0 Hr.
Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202D 2006-2007 Explorer, 2007 1.2 Hrs.
Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel
Clearcoat Cracking > Page 5811
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
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise
At Low Speeds > Page 5816
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft(R) Silicone Spray
Lubricant with an extension nozzle. (Figures 1 and 2)
4. Clean any excess lubricant off the wheel with a soft cloth.
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
091102A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace One Wheel
and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091102B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace Two
Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091102C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise
At Low Speeds > Page 5817
MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire
Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
091102D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive,
Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From
Wheels When Turning > Page 5822
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension
nozzle. (Figures 1 and 2)
NOTE
NEW WHEELS WILL NOT REQUIRE LUBRICATION.
4. Clean any excess lubricate off the wheel with a soft cloth.
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
072304A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining
Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance
Wheel Assembly (Do Not Use With 1007A, 1007A1)
072304B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two
Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
072304C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From
Wheels When Turning > Page 5823
Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS,
Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
072304D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Technical Service
Bulletins > All Other Service Bulletins for Brake Bleeding: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking > Page 5828
071202B 2006-2007 Explorer, 2007 0.7 Hr.
Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202C 2006-2007 Explorer, 2007 1.0 Hr.
Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202D 2006-2007 Explorer, 2007 1.2 Hrs.
Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake System Bleeding
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Special Tools
Material
Master Cylinder Bleeding
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in personal injury.
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
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 new installation,
air may get into the system and cause spongy brake pedal feel. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be gravity bled,
manually bled or bled using pressure bleeding equipment.
1. NOTE: When a new brake master cylinder has been installed or the system has been emptied or
partially emptied, it should be primed to prevent
air from getting into the system.
Disconnect the brake master cylinder tubes.
2. NOTE: Original equipment tubes are not intended to be used during this procedure.
Install the 2 short brake tubes with the ends submerged in the brake master cylinder reservoir and
fill the brake master cylinder reservoir with clean, specified brake fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake System Bleeding > Page 5831
3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air
bubbles. 4. Remove the 2 short brake tubes and install the 2 master cylinder brake tubes. 5. Bleed
each brake tube at the brake master cylinder as follows:
1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant
maintain pressure on the brake pedal while tightening the brake tube fitting.
3 Repeat this operation until clear, bubble-free fluid comes out.
4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front
brake tube.
6. While the assistant maintains pressure on the brake pedal, tighten the master cylinder brake
tubes.
^ Tighten to 18 Nm (13 ft. lbs.).
Brake Caliper Bleeding
NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened
part of the system.
1. Connect one end of a clear flexible hose to the bleeder screw. Submerge the other end in a
container partially filled with clean, specified brake
fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Open the caliper bleeder screw until brake fluid flows into the container. 4. When fluid stops
flowing, close the bleeder screw.
^ Tighten to 10 Nm (89 inch lbs.) for the front brake bleeder screw and 22 Nm (16 ft. lbs.) for the
rear brake bleeder screw.
5. Repeat the previous 3 steps until there are no air bubbles in the brake fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake System Bleeding > Page 5832
Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU)
Bleeding
Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is
required only when a new HCU is installed.
1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure
to bleed the system. Begin at the RH rear caliper.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service
Bulletins > Customer Interest for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Pedal Assy: Customer Interest Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service
Bulletins > Customer Interest for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 5841
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Pedal Assy: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Pedal Assy: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel >
Page 5847
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Technical Service
Bulletins > Page 5848
Brake Pedal Assy: Description and Operation
Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver
can adjust the brake and accelerator pedals for a more comfortable driving position. For removal
and installation of the adjustable pedals, refer to Brake Pedal and Bracket.
Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational
with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward
using the adjustable pedal switch.
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket
Brake Pedal Assy: Service and Repair Brake Pedal and Bracket
Brake Pedal and Bracket
NOTE: Adjustable pedals shown, fixed pedals similar.
Note: Adjustable Pedals Shown, Fixed Pedals Similar.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 5851
Removal
1. NOTE: If equipped with adjustable pedals, when removing the adjustable pedal assembly, make
sure the pedals are adjusted to the full forward
position.
Depower the supplemental restraint system (SRS). For additional information, refer to Air Bag
Systems.
2. CAUTION: The brake pedal must be connected to the booster rod, in an at-rest position, before
removing the stoplamp switch and speed
control deactivator switch or the switch will be damaged.
Remove the stoplamp switch.
3. Remove the speed control deactivator switch. For additional information, refer to Heating and Air
Conditioning.
4. NOTE: The booster push rod clevis locking pin is a one-time use only part. Anytime the booster
push rod clevis locking pin is removed, a new
booster push rod clevis locking pin should be used.
NOTE: Remove the clevis locking pin by squeezing the locking tabs and pulling outward on the
opposite end.
Remove the booster push rod clevis locking pin and discard.
5. Disconnect the brake booster rod from the brake pedal and position aside. 6. If equipped with
power adjustable pedals, disconnect the adjustable pedal motor electrical connector. 7. If equipped
with adjustable pedals, disconnect the accelerator pedal motor electrical connector. 8. Remove and
discard the 2 brake pedal bracket bolts. 9. Remove and discard the 4 brake booster nuts.
10. Position the brake master cylinder and brake booster assembly forward to allow the brake
pedal assembly to clear the studs. 11. Remove the 3 accelerator pedal bracket nuts. 12. Remove
the 2 steering column opening cover screws and the steering column opening cover panel.
13. CAUTION: Do not allow the steering wheel to rotate while the steering column intermediate
shaft is disconnected or damage to the
clockspring can result. If there is evidence the steering column shaft has rotated, the clockspring
must be removed and centered. For additional information, refer to Air Bag Systems.
Secure the steering wheel using a suitable holding device.
14. Remove the steering column shaft bolt and separate the steering shafts. 15. Remove the brake
pedal assembly from the vehicle.
Installation
1. Position the brake pedal assembly in the vehicle. 2. Position the brake master cylinder and brake
booster assembly into the brake pedal bracket assembly. 3. Install the 4 new brake booster nuts.
^ Tighten to 22 Nm (16 ft. lbs.).
4. Install the 2 brake pedal bracket bolts.
^ Tighten to 22 Nm (16 ft. lbs.).
5. Install the 3 accelerator pedal bracket nuts.
^ Tighten to 7 Nm (62 inch lbs.).
6. If equipped with power adjustable pedals, connect the adjustable pedal motor electrical
connector. 7. If equipped with adjustable pedals, connect the accelerator pedal electrical
connector. 8. Position the brake booster push rod to the brake pedal. 9. Install the new booster
push rod clevis locking pin.
10. Connect the steering shafts and install the pinch bolt.
^ Tighten to 30 Nm (22 ft. lbs.).
11. Position the steering column opening cover and install the 2 screws.
12. CAUTION: The brake pedal must be connected to the brake booster rod, in an at-rest position,
before installing the stoplamp switch and
the speed control deactivator switch or the switch will be damaged.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 5852
Install the stoplamp switch.
Install the speed control deactivator switch.
13. Repower the supplemental restraint system (SRS). For additional information, refer to Air Bag
Systems.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Brake Pedal and Bracket > Page 5853
Brake Pedal Assy: Service and Repair Brake Pedal Motor
Brake Pedal Motor
Brake Pedal Motor
Removal and Installation
1. Disconnect the accelerator and brake pedal drive cables from the adjustable pedal motor. 2.
Disconnect the adjustable pedal motor electrical connector. 3. Remove the 2 adjustable pedal
motor screws and then remove the adjustable pedal motor and drive cables as an assembly.
^ To install, tighten to 3 Nm (27 inch lbs.).
4. NOTE: Make sure the brake pedal and the accelerator pedal are in the same position before
connecting the drive cable to the adjustable pedals.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps
Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps
> Page 5863
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps
> Page 5864
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
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise
Over Bumps
Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise
Over Bumps > Page 5870
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise
Over Bumps > Page 5871
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Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 09-9-7 > May > 09 > Engine - FEAD Idler
Pulley Noise During Cold Start
Idler Pulley: All Technical Service Bulletins Engine - FEAD Idler Pulley Noise During Cold Start
TSB 09-9-7
05/18/09
COLD START FEAD HOOT - WHISTLE NOISE
FORD: 2007-2008 Mustang, Expedition, Explorer Sport Trac, Explorer, F-150, F-150
LINCOLN: 2007-2008 Mark LT, Navigator
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 8-4-2 to remove the production build date.
ISSUE Some 2007-2008 F-150, Mustang vehicles equipped with a 4.6L and 5.4L engine;
2007-2008 Mark LT, Expedition, Navigator vehicles equipped with a 5.4L engine; Explorer,
Mountaineer, Explorer Sport Trac vehicles with 4.6L engine may exhibit a front end accessory drive
(FEAD) related high-pitched metallic whistle/hoot noise after a cold soak in ambient temperatures
below 40 °F (4.4 °C). This noise may be caused by the grooved nylon FEAD idler pulley.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
FEAD IDLER PULLEY NOISE MAY BE MOST APPARENT AT OR NEAR COLD ENGINE IDLE
SPEEDS (APPROXIMATELY 1200 RPM). NOISE DURATION IS LESS THAN 10 MINUTES
AFTER STARTUP AND WILL BE ELIMINATED WITH FEAD BELT REMOVED.
1. Replace the nylon FEAD idler pulley, refer to Workshop Manual, Section 303-05.
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
090907A 2007-2008 F-150/Mark LT 0.3 Hr.
4.6L/5.4L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do
Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Expedition/Navigator: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine
Belt (Do Not Use With 8678A, 8620F)
090907A 2007-2008 0.4 Hr.
Explorer/Mountaineer/
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 09-9-7 > May > 09 > Engine - FEAD Idler
Pulley Noise During Cold Start > Page 5877
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 09-9-7 > May > 09 > Engine - FEAD Idler
Pulley Noise During Cold Start > Page 5883
Sport Trac 4.6L: Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt
(Do Not Use With 8678A, 8620F)
090907A 2007-2008 Mustang 4.6L: 0.3 Hr.
Replace FEAD Idler Pulley Includes Time To Remove And Install Serpentine Belt (Do Not Use With
8678A, 8620F)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6C348 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper removal and installation, Front
Brake Caliper: Service and Repair Caliper removal and installation, Front
Brake Caliper
Material
Removal
WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent
damage to brake components and will render the brakes inoperative. Failure to follow these
instructions may result in personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the brake hose flow bolt and position the brake hose
aside.
^ Discard the 2 copper washers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper removal and installation, Front > Page 5886
^ Cap the fluid ports.
3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage
the pistons and boots.
Remove the 2 brake caliper guide pin bolts and the brake caliper. ^
If leaks or damaged boots are found, install a new brake caliper.
Installation
1. CAUTION: Tighten the bottom locator pin brake caliper bolt before tightening the top guide pin
brake caliper bolt.
Position the brake caliper and install the 2 guide pin bolts. ^
Tighten to 72 Nm (53 ft. lbs.).
2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 ft. lbs.).
3. Bleed the brake caliper. 4. Test the brake system for normal operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper removal and installation, Front > Page 5887
Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front
Brake Caliper Anchor Plate
Removal and Installation
1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts and
remove the brake caliper anchor plate.
^ To install, tighten to 165 Nm (122 ft. lbs.).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper removal and installation, Front > Page 5888
Brake Caliper: Service and Repair Caliper removal and installation, Rear
Brake Caliper
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper removal and installation, Front > Page 5889
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the brake flow bolt and position the brake hose aside.
^ Discard the 2 copper washers.
3. Remove the 2 brake caliper guide pin bolts and remove the brake caliper. 4. Remove the brake
pads from the brake caliper. Installation 1. Install the brake pads to the brake caliper. 2. Position
the brake caliper and install the 2 guide pin brake caliper bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 ft. lbs.).
4. Bleed the brake caliper. 5. Test the brake system operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise
Over Bumps
Brake Pad: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise
Over Bumps > Page 5898
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise
Over Bumps > Page 5899
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
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake
Rattling Noise Over Bumps
Brake Pad: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake
Rattling Noise Over Bumps > Page 5905
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 09-22-13 > Nov > 09 > Brakes - Rear Brake
Rattling Noise Over Bumps > Page 5906
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
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Page 5907
Brake Pad: Specifications
Front
Minimum brake pad thickness
...........................................................................................................................................................
3.0 mm (0.118 inch) Maximum brake pad thickness variation (pad-to-pad)
....................................................................................................................... 2.0 mm (0.079 inch)
Maximum brake pad taper wear (in any direction)
............................................................................................................................ 3.0 mm (0.118 inch)
Rear
Minimum brake pad thickness
...........................................................................................................................................................
3.0 mm (0.118 inch) Maximum brake pad thickness variation (pad-to-pad)
....................................................................................................................... 2.0 mm (0.079 inch)
Maximum brake pad taper wear (in any direction)
............................................................................................................................ 3.0 mm (0.118 inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front
Brake Pad: Service and Repair Front
Brake Pads
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5910
Removal
WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent
damage to brake components and will render the brakes inoperative. Failure to follow these
instructions may result in personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
1. Check the brake fluid level in the brake master cylinder reservoir.
^ If required, remove brake fluid until the brake master cylinder reservoir is 1/2 full.
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair
3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage
the pistons and boots.
CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the hose can
occur.
Remove the 2 brake caliper guide pin bolts and position the brake caliper aside. ^
Support the caliper using mechanic's wire.
4. CAUTION: Install new brake pads if they are worn past the specified thickness above the metal
backing plate or rivets. Install new
brake pads in complete axle sets.
Inspect the brake pads for wear and contamination..
5. Inspect the brake disc, machine or install a new front brake disc as necessary. 6. Remove the
brake pads and clips.
^ Discard the clips.
Installation
1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining
material. Do not install contaminated
pads.
NOTE: One brake disc pad kit contains the pads and pad clips required for both sides.
Install the new brake pad clips and the brake pads.
2. CAUTION: Protect the piston and boots when pushing the caliper piston into the caliper piston
bores.
Using a suitable tool and a worn brake pad, compress the disc brake caliper pistons into the
caliper.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5911
3. Position the brake caliper and install the 2 guide pin bolts.
^ Tighten to 72 Nm (53 ft. lbs.).
4. Fill the brake master cylinder reservoir with clean brake fluid. 5. Test the brakes for normal
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5912
Brake Pad: Service and Repair Rear
Brake pads
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 5913
Removal
WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent
damage to brake components and will render the brakes inoperative. Failure to follow these
instructions may result in personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
1. Check the brake fluid level in the brake master cylinder reservoir.
^ If required, remove the fluid until the brake master cylinder reservoir is half full.
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair
3. CAUTION: Do not pry in the caliper sight hole to retract the pistons, as this can damage the
pistons and boots.
CAUTION: Do not allow the brake caliper to hang from the brake hose or damage to the hose can
occur.
Remove the 2 brake caliper guide pin bolts and position the caliper aside. ^
Support the caliper using mechanic's wire.
4. CAUTION: Install new brake pads if they are worn past the specified thickness above the metal
backing plate or rivets. Install new
brake pads in complete axle sets.
Inspect the brake pads for wear and contamination.
5. Inspect the brake disc, machine or install a new front brake disc as necessary. 6. Remove the 2
brake pads.
^ Discard the brake pad clips.
Installation
1. NOTE: One brake disc pad kit contains the linings required for both sides.
Install the brake pad clips and brake pads.
2. CAUTION: Protect the piston and boots when pushing the caliper piston into the caliper piston
bores.
If installing new brake pads, using a suitable tool and a worn brake pad, compress the disc brake
caliper pistons into the caliper.
3. Position the brake caliper and install the 2 brake caliper guide pin bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
4. Fill the brake master cylinder reservoir with clean, specified brake fluid. 5. Test the brakes for
normal operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications
Brake Rotor/Disc: Specifications
Front Brake Disc
Front minimum brake disc thickness
................................................................................................................................................. 28.5
mm (1.12 inch) Minimum thickness to machine front disc
......................................................................................................................................... 29.1 mm
(1.15 inch)
Rear Brake Disc
Minimum rear brake disc thickness
................................................................................................................................................... 11.0
mm (0.43 inch) Minimum thickness to machine rear disc
........................................................................................................................................... 11.6 mm
(0.45 inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures
Brake Rotor/Disc: Procedures
Brake Disc Machining
Material
CAUTION: Do not use a bench lathe to machine the brake discs.
NOTE: Read the entire operating manual and view the video shipped with the lathe before
installing, operating or repairing the lathe.
NOTE: If the thickness of the brake disc is less than the minimum thickness to machine
specification, install a new brake disc. This will make sure that the brake disc will be above
minimum thickness after machining.
NOTE: Do not machine new brake discs.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct
adjustment of the on-vehicle brake lathe will make sure that these dimensions are within
specifications.
1. NOTE: It is not necessary to disconnect the brake line from the brake caliper.
Position the brake caliper and brake caliper anchor bracket aside.
2. For vehicles with a 2-piece brake disc and hub assembly:
1 Mark the brake disc and the wheel stud for correct indexing during re-assembly.
2 Remove the brake disc from the hub.
3 CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective
finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion
protection and brake disc lateral runout.
Remove corrosion from the wheel mounting surface, both disc mounting surfaces and hub
mounting surface.
4 Align the match marks and install the brake disc on the hub.
3. Machine the brake disc using an on-vehicle brake lathe.
1 Install the hub adapter and silencer belt if necessary.
2 Install the cutting lathe.
3 If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated
reading (TIR) target is 0.000 mm (0.000 inch), maximum is 0.08 mm (0.003 inch).
4 Center the cutting head, adjust the cutting bits and install the chip deflector.
5 NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface
finish.
Machine the brake disc.
6 Remove the lathe and, if installed, the silencer belt.
7 Remove the hub adapter.
4. Remove the metal shavings. 5. For vehicles with a 2-piece brake disc and hub assembly:
1 Remove the brake disc from the hub.
2 Remove metal shavings from the hub, the brake disc mounting surfaces and from the ABS
sensors.
3 Apply anti-seize lubricant to the hub mounting surface to prevent corrosion.
4 Align the match marks and install the brake disc on the hub.
6. NOTE: It is not required to install new brake pads if friction material properties are within
guidelines. For additional information, refer to Brake
Pads.
Install the brake caliper and brake caliper anchor bracket.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 5919
Brake Rotor/Disc: Removal and Replacement
Disc Removal and Installation, Front
Brake Disc
Material
Removal
1. CAUTION: Do not allow the brake caliper, brake pads and anchor plate assembly to hang from
the brake hose or damage to the hose
can occur.
Remove the 2 brake caliper anchor plate bolts and position the brake caliper, brake pads and
anchor plate assembly aside. ^
Support the caliper, brake pads and anchor plate assembly using mechanic's wire.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 5920
2. NOTE: If the brake disc cannot be removed easily, apply rust penetrant on the brake disc-to-hub
mating surfaces.
Remove the brake disc.
Installation
1. Clean any rust or foreign material from brake disc and wheel hub.
^ Use parts cleaner to clean the front brake disc and hub surfaces.
2. Apply a thin coat of anti-seize lubricant to the hub flange. 3. Install the brake disc. 4. Position the
brake caliper, brake pads and brake caliper anchor plate assembly and install the 2 brake caliper
anchor plate bolts.
^ Tighten to 165 Nm (122 ft. lbs.).
Disc Removal and Installation, Rear
Brake Disc
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 5921
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair
2. CAUTION: Do not pry in the caliper sight hole to retract the pistons, as this can damage the
pistons and boots.
CAUTION: Do not allow the brake caliper and brake pad assembly to hang from the brake hose or
damage to the hose can occur.
Remove the 2 brake caliper guide pin bolts, position the caliper and pads aside as an assembly. ^
Support the caliper and brake pad assembly using mechanic's wire.
3. NOTE: If the brake disc binds on the parking brake shoe and lining, remove the adjustment hole
knockout panel or access plug and contract the
parking brake shoe and lining.
NOTE: If the brake disc cannot be removed easily, apply penetrating lock lubricant on the brake
disc-to-hub mating surfaces.
Remove the brake disc.
Installation
NOTE: If the adjustment hole knockout panel or access plug was removed, it is necessary to install
an access plug to prevent the entry of contaminants.
1. Clean any rust or foreign material from brake disc and wheel hub.
^ Use parts cleaner to clean the front brake disc and hub surfaces.
2. Install the brake disc. 3. Position the brake caliper and brake pad assembly. Install the 2 brake
caliper guide pin bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
4. Test the brakes for normal operation.
Brake Disc Shield, Front
Brake Disc Shield
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 5922
Brake Disc Shield
Removal and Installation
1. Remove the brake disc. 2. Remove and discard the 4 brake disc shield bolts.
^ To install, tighten to 8 Nm (71 inch lbs.).
3. Remove the brake disc shield. 4. To install, reverse the removal procedure.
Brake Disc Shield, Rear
Brake Disc Shield
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Procedures > Page 5923
Removal
1. Remove the parking brake shoes. 2. Remove the brake disc shield bolts. 3. Cut the shield at the
perforations and remove the brake disc shield halves.
Installation
1. NOTE: If installing a new brake disc shield, cut the new shield in half at the perforations.
Position the brake disc shield halves, and install 2 bolts in each half. ^
Tighten to 8 Nm (71 inch lbs.).
2. Install the parking brake shoes.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Bleeding: By Symptom Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > By Symptom for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel >
Page 5933
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal
Feel
Brake Bleeding: Customer Interest Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > Customer Interest for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal
Feel > Page 5939
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor
Brake Pedal Feel
Brake Bleeding: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Bleeding: > 09-1-6 > Jan > 09 > Brakes - Poor
Brake Pedal Feel > Page 5945
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake System Bleeding
Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Special Tools
Material
Master Cylinder Bleeding
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in personal injury.
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
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 new installation,
air may get into the system and cause spongy brake pedal feel. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be gravity bled,
manually bled or bled using pressure bleeding equipment.
1. NOTE: When a new brake master cylinder has been installed or the system has been emptied or
partially emptied, it should be primed to prevent
air from getting into the system.
Disconnect the brake master cylinder tubes.
2. NOTE: Original equipment tubes are not intended to be used during this procedure.
Install the 2 short brake tubes with the ends submerged in the brake master cylinder reservoir and
fill the brake master cylinder reservoir with clean, specified brake fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake System Bleeding > Page 5948
3. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes without air
bubbles. 4. Remove the 2 short brake tubes and install the 2 master cylinder brake tubes. 5. Bleed
each brake tube at the brake master cylinder as follows:
1 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
2 Loosen the rear brake tube fitting until a stream of brake fluid comes out. Have an assistant
maintain pressure on the brake pedal while tightening the brake tube fitting.
3 Repeat this operation until clear, bubble-free fluid comes out.
4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front
brake tube.
6. While the assistant maintains pressure on the brake pedal, tighten the master cylinder brake
tubes.
^ Tighten to 18 Nm (13 ft. lbs.).
Brake Caliper Bleeding
NOTE: It is not necessary to bleed the entire brake system. It is possible to bleed only the opened
part of the system.
1. Connect one end of a clear flexible hose to the bleeder screw. Submerge the other end in a
container partially filled with clean, specified brake
fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Open the caliper bleeder screw until brake fluid flows into the container. 4. When fluid stops
flowing, close the bleeder screw.
^ Tighten to 10 Nm (89 inch lbs.) for the front brake bleeder screw and 22 Nm (16 ft. lbs.) for the
rear brake bleeder screw.
5. Repeat the previous 3 steps until there are no air bubbles in the brake fluid.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake System Bleeding > Page 5949
Brake Bleeding: Service and Repair Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU)
Bleeding
Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is
required only when a new HCU is installed.
1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure
to bleed the system. Begin at the RH rear caliper.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 >
Brakes - Rear Brake Rattling Noise Over Bumps
Brake Caliper: All Technical Service Bulletins Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 >
Brakes - Rear Brake Rattling Noise Over Bumps > Page 5958
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 09-22-13 > Nov > 09 >
Brakes - Rear Brake Rattling Noise Over Bumps > Page 5959
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Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear
Brake Rattling Noise Over Bumps
Brake Caliper: Customer Interest Brakes - Rear Brake Rattling Noise Over Bumps
TSB 09-22-13
11/16/09
REAR BRAKE RATTLE OVER BUMPS
FORD: 2007-2010 Explorer Sport Trac, Explorer
MERCURY: 2007-2010 Mountaineer
This article supersedes TSB 7-24-6 to update the vehicle model years covered.
ISSUE Some 2007-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles may exhibit a
rattle noise over bumps from the rear of the vehicle. The noise is due to the rear brakes which do
not incorporate an anti-rattle clip.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To repair the rattle noise perform the following:
1. Remove the rear tires as per the Work Shop Manual (WSM), Section 204-04.
2. Remove the brake caliper assembly from the steering knuckle assembly per WSM, Section
206-04.
3. Support the caliper to prevent damage to the brake line. (Figure 1)
4. Remove the outer and inner brake pad and discard pads.
5. Remove the brake pad slippers from the caliper rails and discard.
6. Clean the caliper rails with a wire brush.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear
Brake Rattling Noise Over Bumps > Page 5965
7. Place a thin bead of Motorcraft(R) Silicone Gasket and Sealant on center section of the
underside of the brake pad slippers. (Figure 2)
8. Install the brake pad slippers on to the caliper rails. The smaller brake pad slipper is attached to
the upper caliper rail. The larger brake pad slipper is
attached to the lower caliper rail with the anti rattle loop facing away from the rotor. (Figure 3)
9. Clean any excess Motorcraft(R) Silicone Gasket and Sealant off of the slippers.
10. Remove the caliper pin sleeves and rubber boots.
11. Install new pin caliper boots.
12. Place caliper slide grease into the pin sleeve boots.
13. Install caliper slide pin into the rubber boots.
14. Clean any excess grease off of caliper.
15. Install inner and outer brake pads.
NOTE
THE BRAKE PADS ARE LABELED L FOR LEFT SIDE AND R FOR RIGHT SIDE ON THE STEEL
BACKING PLATE.
16. Install brake caliper as per WSM, Section 206-04.
17. Repeat steps 2-16 on the other side.
18. Install the rear tires as per the WSM, Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 09-22-13 > Nov > 09 > Brakes - Rear
Brake Rattling Noise Over Bumps > Page 5966
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
092213A 2007-2010 Explorer, 0.8 Hr.
Mountaineer, Explorer Sport Trac: Replace The Rear Brake Pads Both Sides Following The
Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2200 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper removal and installation, Front
Brake Caliper: Service and Repair Caliper removal and installation, Front
Brake Caliper
Material
Removal
WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent
damage to brake components and will render the brakes inoperative. Failure to follow these
instructions may result in personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the brake hose flow bolt and position the brake hose
aside.
^ Discard the 2 copper washers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper removal and installation, Front > Page 5969
^ Cap the fluid ports.
3. CAUTION: Do not pry in the brake caliper sight hole to retract the pistons as this can damage
the pistons and boots.
Remove the 2 brake caliper guide pin bolts and the brake caliper. ^
If leaks or damaged boots are found, install a new brake caliper.
Installation
1. CAUTION: Tighten the bottom locator pin brake caliper bolt before tightening the top guide pin
brake caliper bolt.
Position the brake caliper and install the 2 guide pin bolts. ^
Tighten to 72 Nm (53 ft. lbs.).
2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 ft. lbs.).
3. Bleed the brake caliper. 4. Test the brake system for normal operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper removal and installation, Front > Page 5970
Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front
Brake Caliper Anchor Plate
Removal and Installation
1. Remove the brake pads. 2. Remove and discard the 2 brake caliper anchor plate bolts and
remove the brake caliper anchor plate.
^ To install, tighten to 165 Nm (122 ft. lbs.).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper removal and installation, Front > Page 5971
Brake Caliper: Service and Repair Caliper removal and installation, Rear
Brake Caliper
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper removal and installation, Front > Page 5972
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the brake flow bolt and position the brake hose aside.
^ Discard the 2 copper washers.
3. Remove the 2 brake caliper guide pin bolts and remove the brake caliper. 4. Remove the brake
pads from the brake caliper. Installation 1. Install the brake pads to the brake caliper. 2. Position
the brake caliper and install the 2 guide pin brake caliper bolts.
^ Tighten to 32 Nm (24 ft. lbs.).
3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt.
^ Tighten to 35 Nm (26 ft. lbs.).
4. Bleed the brake caliper. 5. Test the brake system operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications
Brake Fluid: Specifications
BRAKE FLUID
Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid
Ford Part Number ................................................................................................................................
................................................... PM-1 or PM-1-C Ford Specification
......................................................................................................................................................
ESA-M6C25-A or WSS-M6C62-A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 5979
C124
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair > Procedures
Hydraulic Control Assembly - Antilock Brakes: Procedures
Anti-Lock Brake System (ABS) Hydraulic Control Unit (HCU) Bleeding NOTE: This procedure is
required only when a new HCU is installed.
1. Connect the scan tool and follow the ABS bleed instructions. 2. Use the caliper bleed procedure
to bleed the system. Begin at the RH rear caliper.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair > Procedures > Page 5984
Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement
Hydraulic Control Unit (HCU)
Material
Removal and Installation
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative. Failure to follow these instructions may
result in personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair > Procedures > Page 5985
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the battery tray. 3. Disconnect the anti-lock brake
system (ABS) module electrical connector.
4. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 2 brake tube-to-hydraulic control unit (HCU) fittings and position the brake tubes
aside. ^
To install, tighten to 23 Nm (17 ft. lbs.).
5. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 4 brake tube-to-HCU extension tube fittings. ^
To install, tighten to 18 Nm (13 ft. lbs.).
6. Remove the 3 HCU bracket-to-frame nuts.
^ To install, tighten to 23 Nm (17 ft. lbs.).
7. Remove the HCU assembly.
8. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 4 HCU extension tube-to-HCU fittings. ^
To install, tighten to 18 Nm (13 ft. lbs.).
9. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer
assembly.
^ To install, tighten to 9 Nm (80 inch lbs.).
10. Remove the bracket-to-HCU bolts and the HCU bracket.
^ To install, tighten to 9 Nm (80 inch lbs.).
11. To install, reverse the removal procedure.
^ Bleed the brake system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder Bypass Condition
Brake Master Cylinder: Testing and Inspection Brake Master Cylinder Bypass Condition
Brake Master Cylinder Bypass Condition
1. Disconnect the brake tubes at the brake master cylinder. 2. Plug the outlet ports of the brake
master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master
cylinder has an internal leak and must be rebuilt or a new master
cylinder must be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Brake Master Cylinder Bypass Condition > Page 5990
Brake Master Cylinder: Testing and Inspection Compensator Port
Compensator Port The purpose of the compensator ports in the brake master cylinder is to supply
any additional brake fluid required by the system due to brake pad wear and to allow brake fluid
returning from the brake tubes to the brake master cylinder to enter the brake master cylinder
reservoir.
The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir.
Turbulence seen in the brake master cylinder reservoir upon application or release of the brake
pedal is normal and shows that the compensating ports are not plugged.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Page 5991
Brake Master Cylinder: Service and Repair
Brake Master Cylinder
Material
Removal and Installation
WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to
brake components and will render the brakes inoperative. Failure to follow these instructions may
result in personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Page 5992
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Use a
suitable suction device to drain the brake master cylinder reservoir. 3. Disconnect the brake fluid
level warning switch electrical connector. 4. Disconnect the 2 brake tube fittings from the brake
master cylinder.
^ To install, tighten to 18 Nm (13 ft. lbs.).
5. Remove the 2 nuts, the brake master cylinder and the square cut seal.
^ To install, tighten to 25 Nm (18 ft. lbs.).
6. NOTE: Make sure that the square cut seal is properly installed or incorrect brake pedal feel can
occur.
To install, reverse the removal procedure. ^
Bleed the brake system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release
Parking Brake Cable: Service and Repair Parking Brake Cable Tension Release
Parking Brake Cable Tension Release
1. Remove the LH cowl side trim panel. 2. With the help of an assistant, release the parking brake
cable tension by pulling down on the intermediate cable at the cable-to-cable connector clip
until the parking brake control sector rotates to its stop and a 4 mm (0.15 inch) x 150 mm (5.9 inch)
retainer pin can be inserted.
3. NOTE: Make sure the cable-to-cable connector clip is connected to the front and rear cable
before removing the brake control retaining pin, and
the cable tension is reloaded slowly.
Disconnect the cable-to-cable connector clip.
4. To reload the tension on the parking brake cable, follow the release procedure in reverse.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release > Page 5998
Parking Brake Cable: Service and Repair Parking Brake Cable - Rear, LH
Parking Brake Cable - Rear, LH
Paring Brake Cable - Rear, LH
Removal and Installation
1. Release the parking brake cable tension. 2. With the vehicle in NEUTRAL, position it on a hoist.
For additional information, refer to Maintenance/Service and Repair 3. Remove the 2 wire form
bolts.
^ To install, tighten to 15 Nm (11 ft. lbs.).
4. Disconnect the intermediate cable from the LH rear cable at the cable equalizer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release > Page 5999
5. Disconnect the front of the LH rear cable conduit at the frame bracket. 6. Disconnect the LH
parking brake cable from the parking brake lever and remove the cable. 7. To install, reverse the
removal procedure.
^ Test the parking brake system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release > Page 6000
Parking Brake Cable: Service and Repair Parking Brake Cable - Rear, RH
Parking Brake Cable - Rear, RH
Parking Brake Cable - Rear, RH
Removal and Installation
1. Release the parking brake cable tension. 2. With the vehicle in NEUTRAL position it on a hoist.
For additional information, refer to Maintenance/Service and Repair 3. Remove the 2 wire form
bolts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release > Page 6001
^ To install, tighten to 15 Nm (11 ft. lbs.).
4. Remove the 2 parking brake cable bracket-to-crossmember bolts.
^ To install, tighten to 15 Nm (11 ft. lbs.).
5. Disconnect the intermediate parking brake cable from the RH rear parking brake cable at the
parking brake cable equalizer. 6. Disconnect the front of the RH parking brake cable conduit at the
frame bracket. 7. Disconnect the RH parking brake cable from the parking brake lever and remove
the parking brake cable. 8. To install, reverse the removal procedure.
^ Test the parking brake system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release > Page 6002
Parking Brake Cable: Service and Repair Parking Brake Cable - Front
Parking Brake Cable - Front
Parking Brake Cable - Front (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release > Page 6003
Parking Brake Cable - Front (Part 2)
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Remove the screw and the hood latch release handle. 3.
Remove the pin-type retainer and the LH A-pillar lower trim panel. 4. Remove the hood latch
release cable assembly screw and position the release cable assembly aside. 5. Release the
tension on the parking brake cable. For additional information, refer to Parking Brake Cable
Tension Release. 6. Remove the 2 screws and the instrument panel steering column cover. 7.
Remove the 2 parking brake release handle bolts from the bracket.
^ To install, tighten to 3 Nm (27 inch lbs.).
8. Disconnect the parking brake switch electrical connector. 9. Remove the wiring harness bracket
screw and position the harness and bracket aside.
10. Remove the 3 bolts from the parking brake control.
^ To install, tighten to 20 Nm (15 ft. lbs.).
11. Position the carpet aside.
12. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the
cable to be removed.
Disconnect the front parking brake cables from the parking brake control.
13. Disconnect the front parking brake cable conduit from the parking brake control. 14. Disconnect
the front parking brake cable from the bracket and remove the cable. 15. To install, reverse the
removal procedure.
^ Test the parking brake system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Parking Brake Cable Tension Release > Page 6004
Parking Brake Cable: Service and Repair Parking Brake Cable - Intermediate
Parking Brake Cable - Intermediate
NOTE: The equalizer is integral to the intermediate cable.
Note: The Equalizer Is Integral To The Intermediate Cable.
Removal and Installation
1. Release the tension on the parking brake cable. For additional information, refer to Parking
Brake Cable Tension Release. 2. With the vehicle in NEUTRAL, position it on a hoist. For
additional information, refer to Maintenance/Service and Repair 3. Disconnect the intermediate
parking brake cable from the front cable at the cable connector clip. 4. Disconnect the LH and RH
rear parking brake cables from the intermediate parking brake cable at the equalizer. 5. Remove
the intermediate parking brake cable. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair
Parking Brake Control: Service and Repair
Parking Brake Control
Parking Brake Control (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair > Page 6008
Parking Brake Control (Part 2)
Removal and Installation
1. Remove the screw and the hood latch release handle. 2. Remove the pin-type retainer and the
LH A-pillar lower trim panel. 3. Remove the hood latch release cable assembly screw and position
the release cable assembly aside. 4. Release the tension on the parking brake cable. 5. Remove
the 2 screws and the instrument panel steering column cover. 6. Remove the 2 parking brake
release handle bolts from the bracket.
^ To install, tighten to 3 Nm (27 inch lbs.).
7. Disconnect the parking brake switch electrical connector. 8. Remove the wiring harness bracket
screw and position the harness and bracket aside.
9. Remove the 3 bolts from the parking brake control.
^ To install, tighten to 20 Nm (15 ft. lbs.).
10. Position the carpet aside and position the cable conduit grommet up through the floor.
11. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the
cable to be removed.
Disconnect the front parking brake cable and conduit from the parking brake control.
12. Remove the parking brake control from the vehicle. 13. To install, reverse the removal
procedure.
^ Test the parking brake system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Technical Service Bulletins > Customer Interest for Parking Brake Pedal: > 07-17-4 > Sep > 07 > Brakes Parking Brake Release Handle Broken
Parking Brake Pedal: Customer Interest Brakes - Parking Brake Release Handle Broken
TSB 07-17-4
09/03/07
PARKING BRAKE RELEASE HANDLE BREAKS - VEHICLES BUILT BEFORE 1211/2006
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer, and 2007 Explorer Sport Trac vehicles built
prior to 12/1/2006 may exhibit separation of parking brake release handle. The issue has no effect
on brake or parking brake performance.
ACTION Follow the Service Procedure steps to correct the condition by replacing the handle.
SERVICE PROCEDURE
Follow Workshop Manual (WSM), Section 206-05 to replace the parking brake release handle.
NOTE
USE CARE WITH THE WIRE HARNESSES ROUTED IN CLOSE PROXIMITY TO THE
BRACKET. DO NOT INSTALL BRACKET IN A MANNER THAT WOULD ALLOW THE HARNESS
TO BE PINCHED, TRAPPED, OR SMASHED.
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
071704A 2006-2007 0.9 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac Built Before 12/01/2006: Replace The Parking
Brake Control (Do Not Use With 2780A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2780 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 07-17-4 > Sep > 07 >
Brakes - Parking Brake Release Handle Broken
Parking Brake Pedal: All Technical Service Bulletins Brakes - Parking Brake Release Handle
Broken
TSB 07-17-4
09/03/07
PARKING BRAKE RELEASE HANDLE BREAKS - VEHICLES BUILT BEFORE 1211/2006
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer 4dr, Mountaineer, and 2007 Explorer Sport Trac vehicles built
prior to 12/1/2006 may exhibit separation of parking brake release handle. The issue has no effect
on brake or parking brake performance.
ACTION Follow the Service Procedure steps to correct the condition by replacing the handle.
SERVICE PROCEDURE
Follow Workshop Manual (WSM), Section 206-05 to replace the parking brake release handle.
NOTE
USE CARE WITH THE WIRE HARNESSES ROUTED IN CLOSE PROXIMITY TO THE
BRACKET. DO NOT INSTALL BRACKET IN A MANNER THAT WOULD ALLOW THE HARNESS
TO BE PINCHED, TRAPPED, OR SMASHED.
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
071704A 2006-2007 0.9 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac Built Before 12/01/2006: Replace The Parking
Brake Control (Do Not Use With 2780A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2780 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair
Parking Brake Shoe: Service and Repair
Parking Brake Shoes
Special Tools
Removal
NOTE: A parking brake shoe kit contains the linings required for both the LH and RH side.
1. NOTE: Make sure the parking brake control is fully released.
Release the tension on the parking brake cable.
2. Remove the rear brake disc. 3. Remove the parking brake shoe adjusting screw.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Page 6025
4. Remove the parking brake shoe adjusting screw spring. 5. Remove the 2 parking brake shoe
hold-down springs and pins. 6. Remove the parking brake shoe retracting spring and the parking
brake shoes.
Installation
1. Position the parking brake shoes and attach the retracting spring. 2. Install the 2 parking brake
shoe hold-down pins and springs. 3. Install the parking brake shoe adjusting screw spring.
4. NOTE: Completely retract the parking brake adjusting screw before installation.
Install the brake shoe adjusting screw.
5. Using the special tool, measure the inside diameter of the parking brake drum. 6. Adjust the
parking brake shoe clearance of 0.54 mm (0.021 inch) less than the inside diameter of the parking
brake drum.
^ Make sure that the parking brake shoes are correctly centered and measure across the center
point of the shoes.
^ Rotate the parking brake shoe adjuster wheel to achieve the correct parking brake shoe-to-brake
disc clearance.
7. Install the rear brake disc. 8. Reload the tension on the parking brake cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Diagrams
C2015
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor >
Component Information > Locations > Page 6033
C149
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6037
Vacuum Brake Booster: Description and Operation
Brake Booster The vacuum type power brake booster:
^ is a dual diaphragm, vacuum assisted power brake booster.
^ reduces brake pedal force and travel distance.
^ is located on the LH side of the bulkhead in the engine compartment, between the brake pedal
and the 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.
^ traps engine vacuum in the power brake booster when in the CLOSED position.
^ retains vacuum to provide 2-3 power-assisted brake applications with the engine off.
Active Brake Booster With Stability Assist The active brake booster functions like a conventional
brake booster with the added feature that it can be actuated electrically by the stability assist
module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6038
Vacuum Brake Booster: Testing and Inspection
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in
NEUTRAL, stop the engine and apply the parking brake. Apply the brake pedal several times to
exhaust all vacuum in
the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system
is operating, the brake pedal will tend to move
downward under constant foot pressure. If no motion is felt, the brake booster system is not
functioning. Continue with the following steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be
available at the check valve end of the vacuum
booster hose with the engine at idle speed and the transmission in NEUTRAL. If manifold vacuum
is available to the brake booster, connect the vacuum booster hose to the brake booster check
valve and repeat Steps 2 and 3.
5. If no downward movement of the brake pedal is felt, install a new brake booster. 6. Operate the
engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10
minutes. Then apply the brake pedal
with approximately 89 N (20 lbs.) of force. The brake pedal feel should be the same as that noted
with the engine operating. If the brake pedal feels hard (no power assist), install a new brake
booster check valve and retest. If the brake pedal feels spongy, bleed the hydraulic system to
remove air. For additional information, refer to Brake System Bleeding.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6039
Vacuum Brake Booster: Service and Repair
Brake Booster
Brake Booster
Removal and Installation
1. CAUTION: The brake booster check valve must be disconnected from the brake booster prior to
removing the master cylinder or the
master cylinder seal may be drawn into the brake booster.
Disconnect the brake booster check valve from the brake booster to deplete the residual vacuum in
the brake booster.
2. Remove the brake master cylinder.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 6040
3. NOTE: When the repair is complete, make sure that the brake booster solenoid electrical
connector is connected, or use of the vehicle with
key-on or vehicle running will result in diagnostic trouble codes (DTCs) being set.
Disconnect the brake booster solenoid electrical connector.
4. NOTE: The booster push rod clevis locking pin is a one-time use only part. Anytime the booster
push rod clevis locking pin is removed a new
booster push rod clevis locking pin should be used.
Remove the booster push rod clevis locking pin and discard.
5. Disconnect the brake booster rod from the brake pedal and position aside.
6. NOTE: Use new nuts when installing the brake booster.
Remove the 4 brake booster nuts and the booster. ^
To install, tighten to 22 Nm (16 ft. lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Testing and Inspection
Vacuum Brake Booster Check Valve: Testing and Inspection
Check Valve The function of the brake booster check valve is to allow manifold vacuum to enter the
brake booster and prevent the escape of vacuum if manifold vacuum is lost during sustained full
throttle operation.
To test the function of the brake booster check valve:
^ Start and run the engine for at least 10 seconds
^ Operate the brake pedal to check for power assist
^ Disconnect the vacuum booster hose from the brake booster check valve. Do not remove the
brake booster check valve from the brake booster
There should be enough vacuum retained in the brake booster for at least one more
power-assisted brake operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component
Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component
Information > Locations > Page 6048
C239
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake
Control Module: > 06-6-9 > Apr > 06 > ABS/TCS/RCS - Warning Lamp ON/DTC C1440 Set
Electronic Brake Control Module: Customer Interest ABS/TCS/RCS - Warning Lamp ON/DTC
C1440 Set
TSB 06-6-9
04/03/06
ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL
INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Sport Trac vehicles built through
3/16/2006 may exhibit an anti-lock brake system / traction control / roll stability control (ABS / TC /
RSC light) warning lamp illuminated with diagnostic trouble code C1440 pressure transducer main /
primary signal faulted. This may be caused by the integrated control unit (ICU).
ACTION Follow the Service Procedure to determine if the ABS module needs to be replaced.
NOTE
THE BASE BRAKE SYSTEM CONTINUES TO FUNCTION PROPERLY.
SERVICE PROCEDURE
1. Install scan tool, retrieve DTCs and record.
a. If DTC C1440 is retrieved, proceed to Step 2.
b. If DTC C1440 is not retrieved, this TSB does not apply. Proceed with normal diagnostics.
2. Replace the ABS module (2C219). Refer to Workshop Manual, Section 206-09 for Removal and
Installation procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 06-6-9 > Apr > 06 > ABS/TCS/RCS - Warning Lamp ON/DTC C1440 Set
Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS/RCS - Warning Lamp
ON/DTC C1440 Set
TSB 06-6-9
04/03/06
ANTI-LOCK BRAKE SYSTEM / TRACTION CONTROL / ROLL STABILITY CONTROL
INDICATOR (ABS / TC / RSC) WARNING LAMP ON WITH DTC C1440
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Sport Trac vehicles built through
3/16/2006 may exhibit an anti-lock brake system / traction control / roll stability control (ABS / TC /
RSC light) warning lamp illuminated with diagnostic trouble code C1440 pressure transducer main /
primary signal faulted. This may be caused by the integrated control unit (ICU).
ACTION Follow the Service Procedure to determine if the ABS module needs to be replaced.
NOTE
THE BASE BRAKE SYSTEM CONTINUES TO FUNCTION PROPERLY.
SERVICE PROCEDURE
1. Install scan tool, retrieve DTCs and record.
a. If DTC C1440 is retrieved, proceed to Step 2.
b. If DTC C1440 is not retrieved, this TSB does not apply. Proceed with normal diagnostics.
2. Replace the ABS module (2C219). Refer to Workshop Manual, Section 206-09 for Removal and
Installation procedure.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C219 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6063
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6064
C155
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6065
Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
Material
Removal and Installation
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. 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.
CAUTION: Electronic modules are sensitive to electrical charges. The ABS module can be
damaged if exposed to these charges.
NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and
calibrated. Follow the scan tool directions for the calibration procedures. For module configuration,
refer to Information Bus.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Page 6066
1. Remove the hydraulic control unit (HCU).
2. CAUTION: Make sure that the ABS module is properly seated to the HCU and that the torque of
the ABS module screws is correct, or
damage to the components can occur.
Remove the 4 screws and the ABS module. ^
To install, tighten to 2 Nm (18 inch lbs.).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake
Control Module > Component Information > Locations > Page 6070
C239
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations
View 151-15 (Center Console)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 6075
C3073
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 6076
ABS Sensor Block: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 6077
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Booster Vacuum Sensor > Component Information > Locations > Page 6081
C149
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 6085
C124
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair
Lateral Accelerometer: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Service and Repair > Page 6089
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Diagrams
C2015
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Wheel Rotation Sensor
Steering Wheel Rotation Sensor
Removal and Installation
1. Remove the 3 lower steering column cover bolts and the lower steering column cover. 2.
Remove the upper steering column cover. 3. Disconnect the steering wheel rotation sensor
electrical connector. 4. Remove the 2 bolts and the steering wheel rotation sensor. 5. To install,
reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6099
C280
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6100
Traction Control Switch: Service and Repair
Stability/Traction Control Switch
Removal and Installation
1. Remove the 2 floor console center finish panel screws and the floor console center finish panel.
^ To install, tighten to 9 Nm (80 inch lbs.).
2. Apply the parking brake. 3. Move the gear selector lever to the D1 position. 4. Position the
instrument panel center finish panel away from the instrument panel. 5. Disconnect the stability
traction control switch electrical connector and remove the stability traction control switch from the
instrument panel
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Locations > Page 6101
center finish panel.
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left/Right Front > Page 6106
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front
C150
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6109
C440
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6110
C160
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Left Front > Page 6111
C426
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front
Wheel Speed Sensor - Front
Wheel Speed Sensor - Front
Removal and Installation
1. Remove the front brake disc. 2. Disconnect the wheel speed sensor electrical connector. 3.
Remove the wheel speed sensor harness bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 6114
4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor
bolt.
^ To install, tighten to 17 Nm (13 ft. lbs.).
6. Remove the wheel speed sensor and the harness. 7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 6115
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair 2. Disconnect the wheel speed sensor electrical connector. 3.
Disconnect the wheel speed harness from the retainers. 4. Remove the wheel speed sensor bolt
and the wheel speed sensor.
^ To install, tighten to 8 Nm (71 inch lbs.).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair
Yaw Rate Sensor: Service and Repair
Stability Control Sensor Cluster
Stability Control Sensor Cluster
Removal and Installation
NOTE: When installing a new stability control sensor cluster, the anti-lock brake system (ABS)
module must be calibrated. Follow the scan tool directions for the calibration procedures.
1. Remove the pin-type retainer and the driver side floor console finish panel.
2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Service and Repair > Page 6119
^ To install, tighten to 9 Nm (80 inch lbs.).
3. Remove the 2 screws and LH heater duct.
4. Disconnect the stability control sensor cluster electrical connector. 5. Remove the stability
control sensor cluster electrical harness retainers and position aside. 6. Remove the 2 stability
control sensor cluster bracket nuts and the stability control sensor cluster.
^ To install, tighten to 7 Nm (62 inch lbs.).
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair
Ignition Switch Lock Cylinder: Service and Repair
IGNITION LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the ignition lock cylinder. 2. To install, reverse the removal procedure.
- Lubricate the ignition lock cylinder during installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 6134
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 6135
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 6136
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 6137
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 6138
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 6139
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 >
Campaign - A/T Shift Lever Circuit Board Replacement > Page 6140
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6146
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6147
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6148
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6149
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6150
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6151
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11
> Jan > 10 > Campaign - A/T Shift Lever Circuit Board Replacement > Page 6152
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Technical Service Bulletins > Page 6153
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Starter Relay > Page 6159
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Testing and Inspection > Run/Start Relay > Page 6162
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
Battery Cable: Service and Repair
BATTERY CABLES
LH Engine Connections (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Page 6167
LH Engine Connections (Part 2)
RH Engine Connections
Removal and Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Page 6168
1. Disconnect the battery. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the nut
and position the battery cable body ground terminal aside.
- To install, tighten to 9 Nm (80 lb-in).
4. Disconnect the battery cable electrical connector. 5. Remove the 2 battery cable locators from
the battery tray. 6. Remove the BJB terminal nuts.
- To install, tighten to 9 Nm (80 lb-in).
7. Position the generator harness terminal aside. 8. Position the BJB terminal aside. 9. Remove the
2 nuts and position the battery cable bracket aside.
- To install, tighten to 20 Nm (15 lb-ft).
10. Remove the nut and position the power steering (P/S) line bracket aside.
- To install, tighten to 12 Nm (9 lb-ft).
11. Remove the nut and position the battery cable engine front cover bracket aside.
- To install, tighten to 9 Nm (80 lb-in).
12. Disconnect the A/C compressor electrical connector. 13. Remove the A/C compressor electrical
connector locator. 14. Remove the bolt and position the battery cable right engine mount bracket
aside.
- To install, tighten to 25 Nm (18 lb-ft).
15. Remove the starter solenoid terminals protective cap. 16. Remove the nut and position the
starter solenoid positive cable terminal aside.
- To install, tighten to 9 Nm (80 lb-in).
17. Remove the nut and position the starter solenoid wire cable terminal aside.
- To install, tighten to 6 Nm (53 lb-in).
18. Remove the nut and position the battery cable engine ground terminal aside.
- To install, tighten to 15 Nm (11 lb-ft).
19. Remove the battery cable. 20. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349
Alternator: Customer Interest Charging System - DTC P0340/P0344/P0345/P0349
TSB 06-19-12
10/02/06
DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V
FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer
2007 Explorer Sport Trac
LINCOLN: 2005-2006 Navigator
MERCURY: 2006 Mountaineer
This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and
service parts updated.
ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005
and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT
vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or
P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a
4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning
diode or open phase connection in the generator.
ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the
generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for
performing a generator frequency test using the WDS oscilloscope function.
SERVICE PROCEDURE
NOTE
USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD
INDICATOR OF A FAULTY GENERATOR.
NOTE
ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE.
1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean
and secure.
2. Attach WDS battery cable clamps to battery/battery cables.
3. Turn on WDS.
4. Select the Toolbox Icon, (upper left of WDS screen).
5. Select Oscilloscope and then click OK.
6. Select Channel 1, Auto, Generator Ripple.
7. Select Calculations, Channel 1, Frequency.
8. Select Calculations again.
9. Push the RUN/STOP button. A waveform should display on the screen.
10. Start the vehicle and leave at idle (engine speed less than 800 RPM).
11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc).
12. Examine the frequency reading on WDS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6178
NOTE
WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED
FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN.
SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT
RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE
FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE.
THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW.
13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave
pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be
adjusted as necessary.
14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform.
15. Determine if the generator is faulty based on frequency measurement:
NOTE
FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR
FREQUENCY READINGS WILL BE INACCURATE.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6179
a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple
frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not
faulty proceed to Step 16.
b. If frequency calculation cannot be made by WDS, it can be calculated manually. See
MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then
generator is faulty and should be replaced. If generator is not faulty proceed to Step 16.
MANUALLY CALCULATE FREQUENCY
^ Count the number of complete voltage dips over a given range of divisions on the scope trace
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6180
^ Divide the number of voltage dips by the number of divisions to get the average voltage
dips/division
^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency
NOTE
THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE
METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE
SLIGHTLY DIFFERENT.
16. If the frequency test does not indicate a fault with the generator, proceed with normal
Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty
vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher.
Calibration files may also be obtained at the website. This new calibration is not included in the B39
CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER,
MOUNTAINEER OR EXPLORER SPORT TRAC).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061912A 2005-2006 0.8 Hr.
Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective
Replace Generator (Do Not Use With 10346A, 10200A)
061912B 2005-2006 Super Duty, 0.9 Hr.
2004-2005 F-150 5.4L 3V:
Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use
With 10346A, 10200A)
061912C 2005-2006 Super Duty, 0.6 Hr.
5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly
Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D,
12650D84)
061912D 2005-2006 Mustang 4.6L 0.8 Hr.
3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not
Use With 10346A 10200A, 9926A, 12650D,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > Customer Interest for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6181
1 2650D84)
061912E 2006 1.1 Hrs.
Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If
Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A,
12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10346 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349
Alternator: All Technical Service Bulletins Charging System - DTC P0340/P0344/P0345/P0349
TSB 06-19-12
10/02/06
DTC P0340/P0344/P0345/P0349-4.6L 3V AND 5.4L 3V
FORD: 2005-2006 Mustang 2004-2005 F-150 2005-2006 Expedition, F-Super Duty 2006 Explorer
2007 Explorer Sport Trac
LINCOLN: 2005-2006 Navigator
MERCURY: 2006 Mountaineer
This article supersedes TSB 06-2-9 to add a production fix date for Expedition and Navigator and
service parts updated.
ISSUE Some 2005-2006 F-Super Duty and Expedition/Navigator vehicles built prior to 12/14/2005
and 2004-2005 F-150 vehicles, equipped with 5.4L 3V engine, and 2005-2006 Mustang GT
vehicles, equipped with 4.6L 3V engine, may exhibit a diagnostic trouble code (DTC) P0340 and/or
P0344; or 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport Trac vehicles equipped with a
4.6L 3V engine may exhibit a DTC P0345 and/or P0349. This may be due to a malfunctioning
diode or open phase connection in the generator.
ACTION Perform a generator frequency test to diagnose cause of concern. Do not replace the
generator unless a frequency test indicates a fault. This TSB provides step-by-step directions for
performing a generator frequency test using the WDS oscilloscope function.
SERVICE PROCEDURE
NOTE
USING THE OSCILLOSCOPE TO MEASURE PEAK-TO-PEAK VOLTAGE IS NOT A GOOD
INDICATOR OF A FAULTY GENERATOR.
NOTE
ENSURE THERE IS NO BATTERY CHARGER CONNECTED TO THE VEHICLE.
1. Ensure the connections to the battery terminals, engine grounds, and generator B+ are clean
and secure.
2. Attach WDS battery cable clamps to battery/battery cables.
3. Turn on WDS.
4. Select the Toolbox Icon, (upper left of WDS screen).
5. Select Oscilloscope and then click OK.
6. Select Channel 1, Auto, Generator Ripple.
7. Select Calculations, Channel 1, Frequency.
8. Select Calculations again.
9. Push the RUN/STOP button. A waveform should display on the screen.
10. Start the vehicle and leave at idle (engine speed less than 800 RPM).
11. Turn on vehicle loads (high beams, blower set on high, heated seats, defroster, etc).
12. Examine the frequency reading on WDS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6187
NOTE
WDS CAN CALCULATE THE FREQUENCY AUTOMATICALLY. THE CALCULATED
FREQUENCY IS LOCATED ON THE LOWER LEFT AREA OF THE OSCILLOSCOPE SCREEN.
SOMETIMES THE FREQUENCY CANNOT BE CALCULATED BECAUSE THE WDS CANNOT
RECOGNIZE AND MEASURE PEAK VALUES. IF THE WDS CANNOT CALCULATE THE
FREQUENCY, IT WILL DISPLAY "INVALID" WHERE THE FREQUENCY READING SHOULD BE.
THIS IS NORMAL IF THE RIPPLE VOLTAGE IS TOO LOW.
13. For a proper visible wave pattern, adjust the voltage scale and time scale until a good wave
pattern is visible. Typically, a setting of 1mS/div and 100mV/div is a good starting point and can be
adjusted as necessary.
14. Run vehicle until signal is steady. Then select the "RUN/STOP" button to freeze the waveform.
15. Determine if the generator is faulty based on frequency measurement:
NOTE
FREQUENCY IS DEPENDENT ON ENGINE RPM. PERFORM ALL TESTS AT IDLE OR
FREQUENCY READINGS WILL BE INACCURATE.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6188
a. Compare the WDS saved waveform to the sample waveforms in Figure 1. If measured ripple
frequency is lower than 500 Hz, then generator is faulty and should be replaced. If generator is not
faulty proceed to Step 16.
b. If frequency calculation cannot be made by WDS, it can be calculated manually. See
MANUALLY CALCULATE FREQUENCY. If calculated ripple frequency is lower than 500 Hz, then
generator is faulty and should be replaced. If generator is not faulty proceed to Step 16.
MANUALLY CALCULATE FREQUENCY
^ Count the number of complete voltage dips over a given range of divisions on the scope trace
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6189
^ Divide the number of voltage dips by the number of divisions to get the average voltage
dips/division
^ Divide the value in Step 2 by the time scale (e.g. 1mS/div = .001 sec/division) to get frequency
NOTE
THIS METHOD OF CALCULATING FREQUENCY IS SLIGHTLY DIFFERENT THAN THE
METHOD USED BY WDS, SO THE FREQUENCY MEASUREMENT VS. CALCULATED MAY BE
SLIGHTLY DIFFERENT.
16. If the frequency test does not indicate a fault with the generator, proceed with normal
Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics for the DTC. For F-Super Duty
vehicles only, if the DTCs are still present after diagnostics, reprogram the powertrain control
module (PCM) to the latest calibration using WDS release B38.11 and higher or B39.2 and higher.
Calibration files may also be obtained at the website. This new calibration is not included in the B39
CD. (DO NOT REPROGRAM EXPEDITION/NAVIGATOR, F-150, MUSTANG, EXPLORER,
MOUNTAINEER OR EXPLORER SPORT TRAC).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061912A 2005-2006 0.8 Hr.
Expedition/Navigator 5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found Defective
Replace Generator (Do Not Use With 10346A, 10200A)
061912B 2005-2006 Super Duty, 0.9 Hr.
2004-2005 F-150 5.4L 3V:
Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not Use
With 10346A, 10200A)
061912C 2005-2006 Super Duty, 0.6 Hr.
5.4L 3V: Diagnose Generator Using WDS, If Generator Is Found To Be Functioning Properly
Reprogram The Powertrain Control Module (Do Not Use With 10346A, 10200A, 12650D,
12650D84)
061912D 2005-2006 Mustang 4.6L 0.8 Hr.
3V: Diagnose Generator Using WDS, If Generator Is Found Defective Replace Generator (Do Not
Use With 10346A 10200A, 9926A, 12650D,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Alternator: > 06-19-12 > Oct > 06 > Charging System - DTC
P0340/P0344/P0345/P0349 > Page 6190
1 2650D84)
061912E 2006 1.1 Hrs.
Explorer/Mountaineer/2007 Explorer Sport Trac 4.6L 3V: Diagnose Generator Using WDS, If
Generator Is Found Defective Replace Generator. (Do Not Use With 10346A 10200A, 9926A,
12650D, 1 2650D84)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10346 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Item.......................................................................................................................................................
..............................................................Specification
Generator
Voltage.................................................................................................................................................
........................................................................12 volts Generator
amps.............................................................................82/135 amps (max) @ 1,800-6,000
generator rpm, approximately 500-2,000 engine rpm
Load at 2,000 rpm................................................................................................................................
........................................................................82 amps No Load at 2,000 rpm....................................
...............................................................................................................................between 13.2 and
15.5 volts
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 6193
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions
Alternator: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6196
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6197
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6198
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6199
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6200
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6201
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6202
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6203
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6204
Alternator: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6205
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6206
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6207
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6208
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6209
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6210
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6211
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6212
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6213
Alternator: Connector Views
C102A
C102B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6214
C102C
C1104A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Diagram Information and Instructions > Page 6215
C1104B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6216
Alternator: Application and ID
Item.......................................................................................................................................................
..............................................................Specification
Generator
Rating........................................................................................................82/135 amp (max) @
1,800-6,000 generator rpm, approx. 500-2,000 engine rpm Generator pulley ratio - early build.........
..............................................................................................................................................................
..........2.72:1 Generator pulley ratio - late build....................................................................................
...............................................................................................2.52:1 Voltage regulator type................
..........................................................................................................................................Electronic
internal with generator
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6217
Alternator: Description and Operation
GENERATOR
The generator is belt-driven by the engine accessory drive system. The generator has an internal
voltage regulator that is not replaced Separately. The generator and voltage regulator are repaired
as an assembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6218
Alternator: Service and Repair
GENERATOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Page 6219
Part 2
Removal and Installation
1. Disconnect the battery. 2. Remove the throttle body. 3. Rotate the front end accessory drive belt
tensioner clockwise and position the front end accessory drive belt aside. 4. Remove the 3 harness
locators from the generator bracket. 5. Remove the 4 bolts and the generator bracket.
- To install, tighten to 10 Nm (89 lb-in).
6. Loosen the 2 bolts and position the generator aside.
- To install, tighten to 25 Nm (18 lb-ft).
7. Disconnect the generator electrical connector. 8. Position the protective cover aside, remove and
discard the nut and position the generator B+ terminal aside.
- To install, tighten to 8 Nm (71 lb-in).
9. Remove the generator.
10. If necessary, remove the nut and the generator pulley.
- To install, tighten to 109 Nm (80 lb-ft).
11. To install, reverse the removal procedure.
- Install a new generator B+ terminal nut.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Service and Repair
Voltage Regulator: Service and Repair
VOLTAGE REGULATOR
Removal and Installation
1. Remove the generator. 2. Remove the 4 screws and the generator voltage regulator (includes
the generator brush and terminal holder).
- To install, tighten to 3 Nm (27 lb-in).
3. NOTE: When installing the voltage regulator (including the generator brush and terminal holder)
assembly, it is necessary to insert a wire
(preferably plastic) into the generator brush holding wire insertion hole in order to hold the
generator brushes while the voltage regulator assembly (including the generator brush and terminal
holder) is being assembled to the generator. Make certain to remove the wire before the vehicle is
started or the generator will not operate.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair
Ignition Lock: Service and Repair
IGNITION LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the ignition lock cylinder. 2. To install, reverse the removal procedure.
- Lubricate the ignition lock cylinder during installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair
Ignition Switch Lock Cylinder: Service and Repair
IGNITION LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. With the ignition switch in the ON position, press the locking pin with a suitable tool and remove
the ignition lock cylinder. 2. To install, reverse the removal procedure.
- Lubricate the ignition lock cylinder during installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement > Page 6239
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement > Page 6240
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement > Page 6241
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement > Page 6242
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement > Page 6243
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement > Page 6244
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Recalls for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign - A/T Shift Lever Circuit
Board Replacement > Page 6245
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement
Technical Service Bulletin # 09B11 Date: 100115
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on January 15, 2010.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6251
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on January 15, 2010. Owner names and
addresses will be available on January 31, 2010.
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 program 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 field
service action.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this service action performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ Ford Motor Company will only refund owner-paid repairs covered by this program if the repair
was performed before the date of the Owner Notification Letter. Non-covered repairs, or those
judged by Ford to be excessive, will not be reimbursed.
^ If a "stuck in park" event occurs, customers can override the brake shift interlock with information
located in the Owner Guide. The 09B11 Owner Letter provides directions to locate the override
information and includes a representative brake shift interlock owner guide attachment. There
should be no emergency repair refunds after the customer mailings are complete.
^ Refunds will only be provided for the cost associated with the diagnosis and replacement of the
transmission gearshift lever due to a "stuck in park" concern.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
^ The refund period for repairs performed prior to the date of the Owner Notification Letter will
expire on July 31, 2010.
^ Refund Claiming Information (submit on separate repair line).
- Program Code: 09B11 - 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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6252
^ 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 prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Refer to ACESII manual for claims preparation and submission information.
^ PROGRAM TERMS: This program will be in effect until January 31, 2011 regardless of mileage.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50415.
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
In some of the affected vehicles, the transmission gearshift lever may not move out of the park
position even when the brake pedal is depressed. This "stuck in park" condition can develop due to
silicon dioxide contamination building up on the contacts of the park detect switch located on the
transmission gearshift lever.
SERVICE PROCEDURE
1. Remove the front floor console. Refer to the appropriate WSM Section 501-12 Console - Front.
2. NOTICE: Electronic modules are sensitive to static electrical charges If the new circuit board is
exposed to these charges, damage may result The
circuit board should be handled by the plastic connector(s) and avoid touching any of the metal
surfaces.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6253
Disconnect the three electrical connectors from the white circuit board that is located on the lower
RH section of the transmission gearshift lever See Figure 1.
3. Remove the circuit board case from the RH side of the transmission gearshift lever by releasing
the two retainer clips See Figure 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6254
4. Replace the circuit board See Figure 3.
^ Separate the upper circuit board case cover from the lower case containing the circuit board.
^ Remove and discard the circuit board Install the new circuit board.
Snap the upper circuit board case cover and the lower case back together.
5. To reinstall the circuit board case, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6255
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6256
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Neutral Safety Switch: > 09B11 > Jan > 10 > Campaign A/T Shift Lever Circuit Board Replacement > Page 6257
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Technical Service Bulletins > Page 6258
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition
Starter Cable: Customer Interest Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > Customer Interest for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition >
Page 6267
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition
Starter Cable: All Technical Service Bulletins Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Cable: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition > Page 6273
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition
Starter Motor: Customer Interest Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > Customer Interest for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank Condition >
Page 6282
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition
Starter Motor: All Technical Service Bulletins Starting System- No Crank Condition
TSB 06-19-14
10/02/06
NO CRANK / STARTER TERMINAL FATIGUE
FORD: 1997-2007 Crown Victoria 1997-2004 F-150 Heritage 1997-2006 Expedition 1998-2006
E-Series 1999-2006 F-Super Duty 2002-2007 Explorer 2004-2006 F-150 2007 Explorer Sport Trac
LINCOLN: 1998-2006 Navigator 2003-2005 Aviator
MERCURY: 1997-2007 Grand Marquis 2002-2007 Mountaineer
ISSUE Some vehicles may exhibit a no crank condition due to an open circuit in the starter relay to
starter motor circuit at the starter motor connection.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
A new starter terminal wiring pigtail kit is released eliminating the need to replace the entire
harness for the terminal connection.
NOTE
TERMINAL KIT ONLY SERVICES THE STARTER RELAY TO STARTER MOTOR CIRCUIT. THE
KIT DOES NOT SERVICE STARTER MOTOR BATTERY POWER CIRCUIT.
Refer to instruction sheet contained in Wiring Pigtail Kit for wiring harness service procedure.
NOTE
REFERENCE THE APPROPRIATE WORKSHOP MANUAL SERVICE SECTION 303-06 FOR
REMOVAL AND INSTALLATION OF THE STARTER MOTOR WIRING TERMINAL CONNECTION
PROCEDURES.
Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty
Coverage
OPERATION DESCRIPTION TIME
061914A Install Wiring Pigtail kit (Do 0.4 Hr.
Not Use With 14200A)
MT061914 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLTS Operation If Available
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Starter Motor: > 06-19-14 > Oct > 06 > Starting System- No Crank
Condition > Page 6288
CONDITION
BASIC PART NO. CODE
14A280 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications
Starter Motor: Electrical Specifications
Item.......................................................................................................................................................
..............................................................Specification
Normal engine cranking speed.............................................................................................................
................................................................140-220 rpm Starter motor no load current draw.................
........................................................................................................................................................6080 amps Starter motor normal load current draw.................................................................................
.............................................................................130-220 amps Starter motor maximum load
current draw..........................................................................................................................................
......................800 amps Starter motor minimum stall torque (at 5
volts)........................................................................................................................................14.7
Nm (10.8 lb-ft) Starter circuit maximum voltage drop (engine at normal operating
temperature).........................................................................................................0.5 volt
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications > Page 6291
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6292
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6293
Starter Motor: Diagrams
C197A
C197B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6294
Starter Motor: Service and Repair
STARTER MOTOR
Removal and Installation
WARNING: When carrying out maintenance on the starting system, be aware that heavy gauge
leads are connected directly to the battery. Make sure protective caps are in place when
maintenance is completed. Failure to follow these instructions may result in personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3.
Remove the starter solenoid terminal cover. 4. Remove the B-terminal nut and disconnect the
cable.
- To install, tighten to 12 Nm (9 lb-ft).
5. Remove the S-terminal nut and disconnect the cable.
- To install, tighten to 6 Nm (53 lb-in).
6. Remove the bolts, the stud bolt and the starter.
- To install, tighten to 25 Nm (18 lb-ft).
7. To install, reverse the removal procedure.
- Tighten the upper bolt before tightening the lower fasteners.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Starter Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Starter Relay > Page 6299
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Run/Start Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Inspection > Run/Start Relay > Page 6302
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Powerpoint, Rear
C474
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Powerpoint, Rear > Page 6308
C3063
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Powerpoint, Rear > Page 6309
C3064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Page 6310
Auxiliary Power Outlet: Service and Repair
PICKUP BED POWER POINT
Removal and Installation
1. Remove the 4 screws and the power point receptacle from the pickup bed side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Page 6311
2. Disconnect the power point receptacle electrical connector and remove the power point
receptacle. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1
C174
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6316
C194
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 6317
C1196
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6322
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6323
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6324
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6325
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6326
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6327
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6328
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6329
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6330
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6331
Fuse: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6334
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6335
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6336
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6337
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6338
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6339
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6340
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6341
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6342
Fuse: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6343
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6344
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6345
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6346
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6347
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6348
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6349
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 6350
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6353
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6354
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6355
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6356
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6357
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6358
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6359
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6360
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6361
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6362
Fuse: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6367
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6368
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6369
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6370
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6371
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6372
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6373
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6374
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6375
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6376
Fuse Block: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6379
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6380
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6381
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6382
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6383
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6384
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6385
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6386
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6387
Fuse Block: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6388
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6389
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6390
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6391
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6392
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6393
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6394
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6395
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6396
Fuse Block: Connector Views
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6397
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6398
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6399
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6400
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 6401
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6404
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6405
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6406
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6407
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6408
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6409
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6410
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6411
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6412
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6413
Fuse Block: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316
Multiple Junction Connector: Diagrams C110-C316
C110
C126
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6424
C133
C134
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6425
C139
C140
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6426
C146
C192
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6427
C210 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6428
C210 (Part 2)
C211
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6429
C212
C213
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6430
C214 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6431
C214 (Part 2)
C215
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6432
C219
C237
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6433
C238
C248
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6434
C300
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6435
C311 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6436
C311 (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6437
C312 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6438
C312 (Part 2)
C313
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6439
C314
C315
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6440
C316
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6441
Multiple Junction Connector: Diagrams C317-C4002
C317
C327
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6442
C328
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6443
C339
C405
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6444
C421
C495
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6445
C510
C511
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6446
C610
C700
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6447
C800
C913
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6448
C3007
C3049
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6449
C3050
C3051
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6450
C3052
C4001
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110-C316 > Page 6451
C4002
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6469
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6470
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6471
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6472
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6473
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6474
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6475
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6476
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6477
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart
Junction Box (SJB) > Page 6478
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6481
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6482
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6483
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6484
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6485
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6488
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6489
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6490
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6491
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6492
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6493
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6494
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6495
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 /
Smart Junction Box (SJB) > Page 6496
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6501
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6502
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6503
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6504
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6505
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6506
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6507
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6508
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6509
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6510
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6513
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6514
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6515
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6516
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Battery Junction Box (BJB) > Page 6517
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6520
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6521
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6522
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6523
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6524
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6525
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6526
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6527
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6528
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Powerpoint, Rear
C474
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Powerpoint, Rear > Page 6534
C3063
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Powerpoint, Rear > Page 6535
C3064
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Page 6536
Auxiliary Power Outlet: Service and Repair
PICKUP BED POWER POINT
Removal and Installation
1. Remove the 4 screws and the power point receptacle from the pickup bed side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Page 6537
2. Disconnect the power point receptacle electrical connector and remove the power point
receptacle. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1
C174
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 6542
C194
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Ignition Transformer Capacitor 1 > Page 6543
C1196
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6548
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6549
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6550
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6551
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6552
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6553
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6554
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6555
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6556
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6557
Fuse: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions
Fuse: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6560
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6561
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6562
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6563
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6564
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6565
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6566
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6567
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6568
Fuse: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6569
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6570
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6571
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6572
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6573
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6574
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6575
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 6576
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6579
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6580
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6581
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6582
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6583
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6584
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6585
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6586
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6587
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6588
Fuse: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6593
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6594
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6595
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6596
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6597
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6598
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6599
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6600
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6601
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6602
Fuse Block: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6605
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6606
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6607
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6608
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6609
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6610
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6611
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6612
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6613
Fuse Block: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6614
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6615
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6616
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6617
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6618
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6619
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6620
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6621
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6622
Fuse Block: Connector Views
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6623
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6624
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6625
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6626
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 6627
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6630
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6631
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6632
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6633
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6634
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6635
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6636
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6637
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6638
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6639
Fuse Block: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316
Multiple Junction Connector: Diagrams C110-C316
C110
C126
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6650
C133
C134
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6651
C139
C140
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6652
C146
C192
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6653
C210 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6654
C210 (Part 2)
C211
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6655
C212
C213
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6656
C214 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6657
C214 (Part 2)
C215
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6658
C219
C237
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6659
C238
C248
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6660
C300
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6661
C311 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6662
C311 (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6663
C312 (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6664
C312 (Part 2)
C313
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6665
C314
C315
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6666
C316
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6667
Multiple Junction Connector: Diagrams C317-C4002
C317
C327
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6668
C328
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6669
C339
C405
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6670
C421
C495
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6671
C510
C511
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6672
C610
C700
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6673
C800
C913
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6674
C3007
C3049
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6675
C3050
C3051
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6676
C3052
C4001
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110-C316 > Page 6677
C4002
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6695
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6696
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6697
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6698
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6699
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6700
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6701
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6702
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6703
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6704
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6707
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6708
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6709
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6710
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 6711
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6714
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6715
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6716
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6717
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6718
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6719
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6720
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6721
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 / Smart Junction Box (SJB) >
Page 6722
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6727
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6728
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6729
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6730
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6731
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6732
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6733
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6734
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6735
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6736
Relay Box: Locations Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB)
Relay Box: Diagrams Battery Junction Box (BJB)
C1035A
C1035B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6739
Relay Box: Diagrams Smart Junction Box (SJB)
C2280A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6740
C2280B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6741
C2280C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6742
C2280D
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery
Junction Box (BJB) > Page 6743
C2280E
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Location
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6746
Passenger Compartment Fuse Panel / Smart Junction Box (SJB)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6747
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6748
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6749
ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6750
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Location
Battery Junction Box (BJB) / Power Distribution Box - Early Production
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6751
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6752
Fuse
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6753
Battery Junction Box (BJB) / Power Distribution Box - Late Production
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 6754
Relay Box: Application and ID Auxiliary Relay Box 1
Auxiliary Relay Box 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 6760
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 6761
Alignment: Specifications General Specifications
General Specifications
General Specifications (Part 1)
General Specifications (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 6762
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 6763
Alignment: Specifications
General Specifications
General Specifications
General Specifications (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications > Page 6764
General Specifications (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6765
Alignment: Description and Operation
Suspension System
The front camber and caster are adjusted by loosening the upper control arm bolts which will allow
the upper arm to be moved in the slotted frame holes. The LF caster can be adjusted by loosening
the lower control arm rearward nut to allow the lower arm to be moved in the slotted frame hole.
Front toe is adjusted by the use of the front wheel spindle tie rods. The rear camber is adjusted by
replacing the upper arm inboard flag nut with a non-flag nut to allow the arm to be adjusted in the
slotted frame holes. The rear toe is adjusted through the use of the rear toe link cam bolt.
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
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
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6766
Positive Toe (Toe In)
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.
Ride Height
Front Ride Height Measurement
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6767
Rear Ride Height Measurement
Thrust Angle (Dogtracking)
Thrust Angle (Dogtracking)
Thrust angle (also known as dogtracking) is the condition in which the rear axle is not square to the
chassis. Heavily crowned roads can give the illusion of incorrect thrust angle.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6768
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, such as wind or road camber.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front
Alignment: Service and Repair Camber and Caster Adjustment - Front
Camber and Caster Adjustment - Front
1. Using alignment equipment and the manufacturer's instructions, measure the front caster and
camber. 2. Loosen the upper arm bolt(s) and adjust the caster and camber settings. Refer to the
chart.
^ When making adjustments that require moving both the front and the rear of the upper arm, move
both ends of the arm equally.
3. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster and camber
settings are not disturbed while tightening the
bolt(s).
Tighten the upper arm bolt(s) to 150 Nm (111 ft. lbs.)
4. NOTE: A caster split adjustment can be made by loosening the LF lower arm rearward nut and
adjusting the rear of the LF lower arm.
Remove and discard the LF lower control arm rearward nut.
5. NOTE: Do not fully tighten the nut and bolt at this time.
Install a new LF lower control arm rearward nut.
6. Position the LF lower control arm until the caster split is within specification.
7. NOTE: Make sure that the weight of the vehicle is on the wheels and that the caster settings are
not disturbed while tightening the nut.
Tighten the LF lower control arm rearward nut to 200 Nm (148 ft. lbs.)
8. Recheck the camber and caster, adjust as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 6771
9. Check and, if necessary, adjust the front toe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 6772
Alignment: Service and Repair Toe Adjustment - Front
Toe Adjustment - Front
1. Using alignment equipment and the manufacturer's instructions, measure the front toe. 2. Start
the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding
device, lock the steering wheel in the straight ahead position.
4. NOTE: Do not allow the steering gear bellows to twist when the front wheel inner tie rod is
rotated.
Remove the clamps.
5. Loosen the tie-rod jam nuts.Rotate the front wheel inner tie rods until the toe setting is within
specification.
6. CAUTION: Make sure to hold the tie-rod end stationary while tightening the nut or damage to the
steering gear bellows can occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the nuts.
Tighten the tie-rod jam nuts to 70 Nm (52 ft. lbs.)
7. Install the clamps. 8. Recheck the toe settings and adjust if necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 6773
Alignment: Service and Repair Toe Adjustment - Rear
Toe Adjustment - Rear
1. Using alignment equipment and the manufacturer's instructions, measure the rear toe. 2. Start
the engine and center the steering wheel. 3. Turn the engine OFF and, using a suitable holding
device, lock the steering wheel in the straight ahead position. 4. Loosen the rear toe link inboard
nut.
5. Rotate the rear toe link cam bolt until the toe setting is within specification.
6. NOTE: Make sure the toe settings are not disturbed while tightening the nut.
While holding the adjustment cam bolt, tighten the toe link inboard nut. ^
Tighten to 275 Nm (202 ft. lbs.)
7. Recheck the toe settings and adjust if necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front > Page 6774
Alignment: Service and Repair Camber Adjustment - Rear
Camber Adjustment - Rear
1. Index-mark the upper arm inboard bolt to the frame.
2. NOTE: The upper arm inboard flag nut must be removed and replaced with a non-flag nut to
allow for the adjustment of the arm in the frame slot.
Remove and discard the upper arm inboard bolt and flagnut. ^
Install a new non-flagnut.Using alignment equipment and the manufacturer's instructions, measure
the rear camber.
3. NOTE: The weight of the vehicle must be off of the wheels in order to adjust the rear camber.
NOTE: For camber adjustment, 1 mm (0.03 inch) of movement equals 0.24 degrees of camber.
NOTE: To decrease the camber, move the upper arm inward. To increase the camber, move the
upper arm outward.
Position the upper arm until the camber setting is within specification.
4. NOTE: Make sure that the camber settings are not disturbed while tightening the nut.
Tighten the upper arm inboard nut to 250 Nm (185 ft. lbs.)
5. Recheck the camber settings and adjust as necessary. 6. Check and, if necessary, adjust the
rear toe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Diagrams
C121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch > Page 6782
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes 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 the transmission electronic pressure control (EPC) pressure during increased
engine load, for example, during parking maneuvers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 6786
C226
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 6791
C226
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection
Tire Pressure Sensor: Testing and Inspection
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Smart Junction Box (SJB).
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Page 6796
6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees)
from the valve stem. Press and release the test
button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the
tire pressure sensor has been recognized by the SJB.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and
the entire procedure must be repeated.
8. Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will be
verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and
document them on the applicable warranty claim.
NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed SJB.
10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry
out the SJB On-Demand Self Test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor can be removed and installed without removing the strap or the cradle.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Dismount the tire only as
instructed.
Remove the tire from the wheel.
2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor locking clip can occur.
Using a pocket screwdriver, or similar tool, remove the sensor locking clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 6799
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor can occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle.
4. Remove the sensor.
Assembly
1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor
installation.
NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise
when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the
cradle and pushing the opposite end of the sensor down onto the cradle.
2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the
sensor locking clip cannot be fully inserted, then
the sensor may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 6800
3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 6801
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 6802
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There
are several different strap kits available based on wheel diameter but all strap kits share the same
base part number.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. Remove the tire pressure monitoring system (TPMS) sensor.
2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and
gloves when removing the TPMS
band/strap. Failure to follow these instructions may result in personal injury.
Remove a factory installed strap in this sequence: 1
Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both
sides of the buckle approximately 25 mm (0.98 inch) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is
fully released from the worm gear.
^ Discard the strap.
3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle
and prying up.
Assembly
1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click"
noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of the sensor down onto the cradle.
2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to
remove the cradle adhesive strip residue.
NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the
valve stem.
Clean the area where the sensor and cradle are to be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 6803
3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH
side when viewed from the curb side (beauty side)
of the wheel.
NOTE: The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel
drop well 180° from the valve stem.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is
positioned in the lowest spot possible for
correct sensor and cradle retention.
NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm
gear. ^
Tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure
Monitoring System (TPMS) Sensor > Page 6804
6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 6809
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. Remove the wheel bearing and hub assembly. 2. Remove the wheel speed sensor harness
bracket bolt from the wheel knuckle.
^ To install, tighten to 8 Nm (71 inch lbs.)
3. Remove and discard the tie-rod end nut.
^ To install, tighten to 103 Nm (76 ft. lbs.)
4. CAUTION: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the tie-rod boot while installing the special tool.
Using the special tool, separate the tie-rod end from the wheel knuckle.
5. Remove and discard the lower ball joint nut.
^ To install, tighten to 150 Nm (111 ft. lbs.)
6. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 6810
7. Remove and discard the upper ball joint nut.
^ To install, tighten to 55 Nm (41 ft. lbs.)
8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint and remove the wheel knuckle.
9. To install, reverse the removal procedure.
^ Check and if necessary, align the front end.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Power Steering System Purging
Special Tool(s)
Material
CAUTION: If the air is not purged from the power steering system correctly, premature power
steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of
aerated fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The
power steering purge procedure must be carried out
prior to any component repair for which power steering noise complaints are accompanied by
evidence of aerated fluid.
Remove the power steering pump reservoir cap. Check the fluid.
2. Raise the front wheels off the floor. 3. Tightly insert the stopper of the vacuum pump into the
reservoir. 4. Start the engine. Install the vacuum pump, apply vacuum and maintain the maximum
vacuum of 68 - 85 kPa (20 - 25 in-Hg). 5. If equipped with Hydro-Boost(R), apply the brake pedal
twice.
6. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a
time. Damage to the power steering pump
can occur.
Cycle the steering wheel fully from stop-to-stop 10 times.
7. Stop the engine. 8. Release the vacuum and remove the vacuum pump.
9. CAUTION: Do not overfill the reservoir.
Fill the reservoir. ^
Use approved transmission fluid.
10. Start the engine. 11. Install the vacuum pump. Apply and maintain the maximum vacuum of 68
- 85 kPa (20 - 25 in-Hg).
12. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a
time. Damage to the power steering pump
can occur.
Cycle the steering wheel fully from stop-to-stop 10 times.
13. Stop the engine, release the vacuum and remove the vacuum pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 6815
14. CAUTION: Do not overfill the reservoir.
Fill the reservoir as needed and install the reservoir cap.
15. Visually inspect the power steering system for leaks.
17. CAUTION: Do not overfill the reservoir.
Fill the reservoir as needed and visually inspect the power steering system for leaks.
18. Install the reservoir cap.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications
Power Steering Fluid: Specifications
POWER STEERING FLUID
Motorcraft MERCON Multi-Purpose ATF
Ford Part Number ................................................................................................................................
.............................................................. MERCON Ford Specification ................................................
............................................................................................................................................ XT-2-QDX
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Page 6819
Power Steering Fluid: Testing and Inspection
Power Steering Fluid Leak Test
NOTE: This test should only be carried out if a leak in the system has not been detected during a
thorough visual inspection. Refer to Inspection and Verification. See: Testing and Inspection/Initial
Inspection and Diagnostic Overview/Inspection and Verification
1. Check the power steering fluid level. If necessary, add the specified power steering fluid. 2.
Remove the power steering pump reservoir cap and tightly install the evacuation cap to the power
steering pump reservoir. 3. Install the hose from the fill adapter manifold tee to the evacuation cap
on the power steering pump reservoir. 4. Install the vacuum pump to the evacuation cap. 5. Using
the vacuum pump, apply 68 - 85 kPa (20 - 25 in-Hg) of vacuum to the power steering system. 6.
Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa
(0.88 in-Hg) a leak is present. 7. Remove the vacuum pump.
8. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to
the power steering pump can occur.
Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C
(165 - 176°F) by rotating the steering wheel fully to the left and right several times.
9. Visually inspect the system for leaks. If a leak is evident, repair as necessary. If a leak is not
evident, add the specified UV fluorescent tracer dye
to the power steering fluid. Use 14.78 mL (1/2 oz) of dye solution for every 1.89 L (2 qt) of power
steering fluid.
10. CAUTION: Do not hold the steering wheel at the stops for more than 3-5 seconds. Damage to
the power steering pump can occur.
Start the engine. With the engine at idle, raise the power steering fluid temperature to 74 - 80°C
(165 - 176°F) by rotating the steering wheel fully to the left and right several times.
11. NOTE: On vehicles with rack and pinion steering gear, it may be necessary to remove the
bellows boot clamp from the steering gear bellows
boots to inspect for internal steering gear leaks.
Using the special tool (UV lamp), inspect the system for traces of UV dye. Repair as necessary.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair
Power Steering Fluid Cooler: Service and Repair
Power Steering Fluid Cooler
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair > Page 6823
Removal and Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Service and Repair > Page 6824
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Release the fluid cooler hose clamp and disconnect the hose
from the fluid reservoir. 3. Remove the LH front splash shield screws, pin-type retainers and the
splash shield.
4. Remove the lower radiator air deflector pushpins and the air deflector.
5. Remove the 2 fluid cooler hose braces. 6. Remove the fluid cooler hose bracket bolt.
^ To install, tighten to 18 Nm (13 ft. lbs.)
7. Remove the steering line clamp plate nut.
^ To install, tighten to 25 Nm (18 ft. lbs.)
8. Rotate the steering line clamp plate and disconnect the fluid cooler return line from the steering
gear.
^ Discard the O-ring seal.
9. Remove the power steering fluid cooler.
10. NOTE: New O-ring seals must be installed whenever the steering lines are disconnected.
To install, reverse the removal procedure. ^
Fill the power steering system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair
Power Steering Fluid Reservoir: Service and Repair
Power Steering Fluid Reservoir
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair > Page 6828
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
1. Using a suitable suction device, drain the power steering fluid reservoir. 2. Remove the power
steering fluid reservoir bolt.
^ To install, tighten to 9 Nm (80 inch lbs.)
3. Release the reservoir-to-pump hose clamp and disconnect the hose. 4. Release the power
steering fluid cooler-to-reservoir hose clamp and disconnect the hose. 5. Remove the power
steering fluid reservoir. 6. To install, reverse the removal procedure.
^ Fill the power steering system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair
Power Steering Line/Hose: Service and Repair
Power Steering Pump to Steering Gear Pressure Line
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Page 6832
Removal
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove the power steering pump pulley. 3. Remove the
steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the fluid cooler
return line from the steering gear.
^ Discard the O-ring seal.
5. Disconnect the pressure line from the steering gear.
^ Discard the O-ring seal.
6. Remove the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Page 6833
7. Remove the pressure line-to-crossmember retainer bracket bolt. 8. Disconnect the pressure
line-to-pump fitting.
^ Remove and discard the Teflon(R) O-ring seal.
9. Remove the pressure line.
Installation
1. NOTE: A new Teflon(R) O-ring seal must be installed.
Using the special tool, install a new Teflon(R) O-ring seal on the pressure line fitting.
2. Position the pressure line and connect the pressure line-to-pump fitting.
^ Tighten to 65 Nm (48 ft. lbs.)
3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L).
^ Tighten to 11 Nm (8 ft. lbs.)
4. NOTE: New O-rings must be installed whenever the power steering lines are disconnected.
Install a new O-ring seal and position the pressure line to the steering gear.
5. Install the pressure line bracket-to-crossmember bolt.
^ Tighten to 12 Nm (9 ft. lbs.)
6. Install a new O-ring seal and position the power steering gear-to-fluid cooler return hose to the
steering gear. Rotate the steering line clamp plate
into position.
7. Install the steering line clamp plate nut.
^ Tighten to 25 Nm (18 ft. lbs.)
8. Install the power steering pump pulley. 9. Fill the power steering system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 - 4.6L
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6838
Removal and Installation
CAUTION: While repairing the power steering system, care should be taken to prevent the entry of
contaminants or premature failure of the power steering components can result.
1. Using a suitable suction device, drain the power steering fluid reservoir. 2. With the vehicle in
NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and
Repair. 3. Remove the power steering pump pulley. 4. Remove the pressure line bracket-to-engine
nut. 5. Compress the clamp and disconnect the reservoir-to-pump hose.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6839
6. Disconnect the pressure line-to-pump fitting.
^ Remove and discard the Teflon(R) O-ring seal.
7. Remove the 2 engine wiring bracket nuts and position the wiring harness and ground cable
aside.
8. Remove the 3 bolts and the power steering pump.
Installation
1. NOTE: A new Teflon(R) O-ring seal must be installed.
Using the special tool, install a new Teflon(R) O-ring seal on the pressure line-to-pump fitting.
2. Position the power steering pump and install the 3 bolts.
^ To install, tighten to 20 Nm (15 ft. lbs.)
3. Position the ground cable and engine wiring bracket. Install the 2 nuts.
^ Tighten to 20 Nm (15 ft. lbs.)
4. Connect the pressure line-to-pump fitting.
^ Tighten to 65 Nm (48 ft. lbs.)
5. Connect the reservoir-to-pump hose. 6. Install the pressure line bracket-to-engine nut.
^ Tighten to 11 Nm (8 ft. lbs.)
7. Install the power steering pump pulley. 8. Fill the power steering system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6840
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Power Steering Pump Pulley - 4.6L
Special Tool(s)
Removal
1. Remove the engine air cleaner outlet pipe. For additional information, refer to Fuel Delivery and
Air Induction. 2. Rotate the tensioner and remove the engine accessory drive belt from the power
steering pump pulley. 3. Using the special tool, remove the pulley.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 6841
Installation
CAUTION: Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint
marks, discard the pulley. If there is no paint or one paint mark, use a paint pencil to mark the web
area of the pulley near the hub.
CAUTION: Installation of a new power steering pump pulley is necessary after being removed and
installed 2 times.
1. Using the special tool, install the pulley.
2. Rotate the tensioner and install the engine accessory drive belt on the power steering pump
pulley. For additional information on accessory drive
belt routing, refer to Drive Belts, Mounts, Brackets and Accessories.
3. Install the engine air cleaner outlet pipe. For additional information, refer to Fuel Delivery and Air
Induction.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Diagrams
C121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Switch
POWER STEERING PRESSURE (PSP) SWITCH
Typical Power Steering Pressure (PSP) Switch
The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch
is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a
low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate
for additional loads on the engine by adjusting the idle RPM and preventing engine stall during
parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic
pressure control (EPC) pressure during increased engine load, for example during parking
maneuvers
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page
6848
Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP)
Sensor
POWER STEERING PRESSURE (PSP) SENSOR
Typical Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes 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 the transmission electronic pressure control (EPC) pressure during increased
engine load, for example, during parking maneuvers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
> Component Information > Locations > Page 6852
C226
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations > Page 6856
C226
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Special Tool(s)
Special Tool(s)
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box
(SJB), located below the LH side of the instrument panel, remove the cover and the restraints
control module (RCM)
fuse 17 (10A) from the SJB.
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 switch to OFF.
6. WARNING: To avoid accidental deployment and possible personal 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
servicing, 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.
The front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6862
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.
2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the
cover.
4. 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.
5. Prove out the SRS as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6863
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment, which can result in personal injury.
- The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always
wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never
probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in
pretensioner, adaptive load limiting retractor or air bag deployment and could 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 reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6864
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart
junction box (SJB), located below the LH side of the instrument panel, remove the cover and the
restraints control module (RCM)
fuse 17 (10A) from the SJB.
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 front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
7. Remove the 2 driver air bag module bolts (1 shown).
8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation.
Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6865
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
10. Open and lower the glove compartment door.
11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield.
12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive
tether squibs do not require deactivation.
Through the glove compartment opening, disconnect the LH side passenger air bag module
electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector on the LH side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6866
14. From under the rear of the passenger seat, detach the passenger seat side air bag module
electrical connector from the seat track bracket. Then
slide and disengage the passenger seat side air bag module electrical connector locking clip, and
then release the tab and disconnect the passenger seat side air bag module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Vehicles without safety canopy modules
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM.
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Explorer and Mountaineer vehicles with safety canopy modules
17. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6867
18. Disconnect the passenger side safety canopy module electrical connector.
19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
20. Release and position aside the driver side C-pillar trim panel.
21. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6868
22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles with safety canopy modules
23. Remove the driver and passenger side upper C-pillar trim panels.
24. Disconnect the passenger side safety canopy module electrical connector.
25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
26. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6869
27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles
28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module
electrical connector locking clip, and then release
the tab and disconnect the driver seat side air bag module electrical connector.
29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the
battery ground cable.
Reactivation
All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6870
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side
air bag module electrical connector.
4. Connect the driver seat side air bag module electrical connector and then slide and engage the
seat side air bag electrical connector locking clip.
Explorer Sport Trac vehicles with safety canopy modules
5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
6. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6871
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy module electrical connector.
8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and
passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles with safety canopy modules
10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
11. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6872
12. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
side safety canopy module electrical connector.
14. Connect the passenger side safety canopy module electrical connector.
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6873
16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
seat side air bag module electrical connector.
17. Connect the passenger seat side air bag module electrical connector and then slide and
engage the seat side air bag electrical connector locking
clip. Then attach the passenger seat side air bag module electrical connector to the seat track
bracket.
18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector on the LH side.
19. Connect the LH side passenger air bag module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6874
20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21.
Close glove compartment door.
22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the
driver air bag module in the wrong
position. Match the electrical connector key to the keyway in the driver air bag module. Do not force
the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted in removal.
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
6875
25. 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.
26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and
install the cover.
28. 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.
29. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch back to ON and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a
scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component
Information > Service and Repair
Steering Column Cover: Service and Repair
STEERING COLUMN COVER
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component
Information > Service and Repair > Page 6879
Part 2
Exploded Views
Removal and Installation
1. Remove the steering column opening cover.
- Remove the 2 screws and remove the cover.
2. Remove the lower and upper steering column covers.
- Remove the 2 screws from the lower steering column cover and remove both covers.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > NHTSA07V181000 > Apr > 07 > Recall
07V181000: Steering Gear Mounting Bolt Replacment
Steering Gear Mount: Recalls Recall 07V181000: Steering Gear Mounting Bolt Replacment
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2007 Ford/Explorer Sport Trac 2007
MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V181000 MFR'S
REPORT DATE: April 24, 2007
COMPONENT: Steering
POTENTIAL NUMBER OF UNITS AFFECTED: 11
SUMMARY: On certain sport utility vehicles, the two bolts that attach the steering gear assembly to
the frame may have been over-tightened. This condition could result in one or both of the bolts
fracturing, causing the steering gear to become loose.
CONSEQUENCE: This condition could cause "clunking" noise when steering as well as decreased
steering effectiveness potentially resulting in a crash.
REMEDY: Dealers will replace both the steering gear assembly mounting bolts and nuts free of
charge. The recall is expected to begin on or about May 5, 2007. Owners may contact Ford at
1-800-392-3673.
NOTES: Ford recall No. 07S52. Customers may 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear
Mounting Bolt Replacement
Technical Service Bulletin # 07S52 Date: 070419
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes. OASIS will be activated by April 19, 2007
FSA VIN LIST ACTIVATED?
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear
Mounting Bolt Replacement > Page 6893
Yes. FSA VIN Lists will be available through the website by April 19, 2007. Owner names and
addresses will be available by May 10, 2007.
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 demonstration or 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
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
In situations where the vehicle is in the shop and parts need to be ordered, Ford Motor Company
will pay for a rental vehicle, except for fuel and insurance which 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
recall claim form.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ 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.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires approval from Special Service Support Center. Refer to ACESII manual for
claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear
Mounting Bolt Replacement > Page 6894
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirements through normal
order processing channels.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
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 program involves replacing the steering gear bolts and nuts.
REPLACEMENT
1. Raise the vehicle on a hoist.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear
Mounting Bolt Replacement > Page 6895
2. Remove the steering gear bolts and nuts. See Figure 1.
3. Install new steering gear bolts and nuts.
4. Tighten the steering gear bolts to 350 Nm (258 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear
Mounting Bolt Replacement > Page 6896
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > Recalls for Steering Gear Mount: > 07S52 > Apr > 07 > Recall - Steering Gear
Mounting Bolt Replacement > Page 6897
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > NHTSA07V181000 >
Apr > 07 > Recall 07V181000: Steering Gear Mounting Bolt Replacment
Steering Gear Mount: All Technical Service Bulletins Recall 07V181000: Steering Gear Mounting
Bolt Replacment
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Explorer 2007 Ford/Explorer Sport Trac 2007
MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V181000 MFR'S
REPORT DATE: April 24, 2007
COMPONENT: Steering
POTENTIAL NUMBER OF UNITS AFFECTED: 11
SUMMARY: On certain sport utility vehicles, the two bolts that attach the steering gear assembly to
the frame may have been over-tightened. This condition could result in one or both of the bolts
fracturing, causing the steering gear to become loose.
CONSEQUENCE: This condition could cause "clunking" noise when steering as well as decreased
steering effectiveness potentially resulting in a crash.
REMEDY: Dealers will replace both the steering gear assembly mounting bolts and nuts free of
charge. The recall is expected to begin on or about May 5, 2007. Owners may contact Ford at
1-800-392-3673.
NOTES: Ford recall No. 07S52. Customers may 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 >
Recall - Steering Gear Mounting Bolt Replacement
Technical Service Bulletin # 07S52 Date: 070419
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes. OASIS will be activated by April 19, 2007
FSA VIN LIST ACTIVATED?
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 >
Recall - Steering Gear Mounting Bolt Replacement > Page 6907
Yes. FSA VIN Lists will be available through the website by April 19, 2007. Owner names and
addresses will be available by May 10, 2007.
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 demonstration or 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
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
In situations where the vehicle is in the shop and parts need to be ordered, Ford Motor Company
will pay for a rental vehicle, except for fuel and insurance which 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
recall claim form.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ 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.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires approval from Special Service Support Center. Refer to ACESII manual for
claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 >
Recall - Steering Gear Mounting Bolt Replacement > Page 6908
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this program. Order your parts requirements through normal
order processing channels.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
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 program involves replacing the steering gear bolts and nuts.
REPLACEMENT
1. Raise the vehicle on a hoist.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 >
Recall - Steering Gear Mounting Bolt Replacement > Page 6909
2. Remove the steering gear bolts and nuts. See Figure 1.
3. Install new steering gear bolts and nuts.
4. Tighten the steering gear bolts to 350 Nm (258 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 >
Recall - Steering Gear Mounting Bolt Replacement > Page 6910
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Mount > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear Mount: > 07S52 > Apr > 07 >
Recall - Steering Gear Mounting Bolt Replacement > Page 6911
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and
Repair > Steering Column Shaft - Upper
Steering Shaft: Service and Repair Steering Column Shaft - Upper
Steering Column Shaft - Upper
Steering Column Shaft - Upper
Removal and Installation
1. CAUTION: Do not allow the steering column shaft to rotate while the intermediate shaft is
disconnected or damage to the clockspring
can result. If there is evidence that the shaft has rotated, the clockspring must be removed and
recentered. For additional information, refer to Air Bag Systems.
Place the steering wheel and the front wheels in the straight-ahead position. ^
Turn the ignition switch to the OFF position and remove the key.
2. Remove and discard the upper steering column shaft-to-steering column bolt.
^ To install, tighten to 30 Nm (22 ft. lbs.)
3. Remove the 3 upper steering column shaft dash seal bolts.
^ To install, tighten to 12 Nm (9 ft. lbs.)
4. Remove and discard the lower steering column shaft-to-upper steering column shaft bolt.
^ To install, tighten to 47 Nm (35 ft. lbs.)
5. Remove the upper steering column shaft.
6. CAUTION: New steering column shaft bolts must be installed.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and
Repair > Steering Column Shaft - Upper > Page 6916
Steering Shaft: Service and Repair Steering Column Shaft - Lower
Steering Column Shaft - Lower
Steering Column Shaft - Lower
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. CAUTION: Do not allow the steering column shaft to rotate while the lower shaft is disconnected
or damage to the clockspring can
result. If there is evidence that the shaft has rotated, the clockspring must be removed and
recentered. For additional information, refer to Air Bag Systems.
Place the steering wheel and the front wheels in the straight-ahead position. ^
Turn the ignition switch to the OFF position and remove the key.
3. Remove and discard the lower steering column shaft-to-steering column shaft bolt.
^ To install, tighten to 47 Nm (35 ft. lbs.)
4. Remove and discard the lower steering column shaft-to-steering gear bolt.
^ To install, tighten to 47 Nm (35 ft. lbs.)
5. Remove the lower steering column shaft. 6. Inspect the lower steering column shaft for boot
damage or separation from the shaft tube.
^ If damage or separation of the lower steering column shaft is evident, install a new lower steering
column shaft.
7. CAUTION: New steering column shaft bolts must be installed.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 6925
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 6931
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 6932
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 6933
C203
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 6934
Steering Wheel: Service and Repair
Steering Wheel
Steering Wheel
Removal and Installation
1. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF
position. 2. Remove the driver air bag module. For additional information, refer to Air Bag Systems.
3. Disconnect the steering wheel switches electrical connector.
4. NOTE: A new bolt must be installed.
Remove the steering wheel bolt and the steering wheel. ^
Discard the bolt.
^ To install, tighten to 40 Nm (30 ft. lbs.)
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair
Tie Rod: Service and Repair
Inner Tie Rod
Special Tool(s)
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 6938
Removal
CAUTION: The boots and clamps are designed to provide an airtight seal and protect the internal
components of the steering gear. If the seal is not airtight the vacuum generated during turning will
draw water and contamination into the gear causing premature damage.
CAUTION: Zip ties do not produce an airtight seal and must not be used.
CAUTION: The inner ball joint grease is not compatible with water and contamination trapped in
the grease will degrade the life of the joint.
CAUTION: If present, the orientation of the vent tube must be noted so the boots and vent tubes
can be installed in the correct location.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Loosen the tie-rod end jam nut. 3. Remove and discard the
tie-rod end nut.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 6939
4. CAUTION: Do not damage the tie-rod boot when installing the special tool.
Using the special tool, separate the tie-rod end from the wheel knuckle.
5. NOTE: Count the number of turns required to remove the tie-rod end for reference during
installation.
Remove the tie-rod end.
6. Remove the tie-rod end jam nut.
7. NOTE: A new outer bellows boot clamp must be installed.
Remove and discard the outer bellows boot clamp.
8. NOTE: A new inner bellows boot clamp must be installed.
Remove and discard the inner bellows boot clamp.
9. Remove the steering gear bellows boot.
10. CAUTION: Place the steering gear at the center position. Use a 1-1/16 inch crowfoot on the flat
of the rack gear to resist rotation and to
prevent damage during removal and installation of the inner tie rod.
NOTE: If repairing the RH side, it will be necessary to pull back the LH inner tie-rod boot to hold the
steering gear.
NOTE: An assistant may be needed for removal of the RH inner tie rod.
Using the special tool, remove the inner tie rod.
11. CAUTION: Thoroughly remove any abrasive material. This material is extremely harmful to the
steering gear.
Thoroughly clean and inspect all the parts to be reused. Install new parts as necessary.
Installation
1. Using the special tool, install the inner tie rod.
^ Tighten to 100 Nm (74 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Page 6940
2. NOTE: Apply steering gear grease to the steering gear bellows boot groove in the inner tie rod.
NOTE: Make sure the steering gear bellows boot is positioned correctly over the steering gear
housing bead and the groove in the inner tie rod.
NOTE: Make sure the steering gear bellows boot is not twisted and the vent tube (if equipped) is
securely inserted into the vent nipple of the steering gear bellows boot.
Install the steering gear bellows boot. Using the special tool, install a new inner bellows boot clamp.
13. NOTE: Make sure the end of the steering gear bellows is positioned between the 2 grooves on
the inner tie rod or an internal leak can result.
Install a new outer bellows boot clamp.
14. Thread the tie-rod end jam nut onto the inner tie rod.
15. NOTE: Install the tie-rod end the same number of turns as recorded during the removal.
Install the tie-rod end to the inner tie rod.
16. Tighten the tie-rod end jam nut.
^ Tighten to 80 Nm (59 ft. lbs.)
8. Position the tie-rod end to the wheel knuckle and install a new tie-rod end nut.
^ Tighten to 103 Nm (76 ft. lbs.)
9. Check and, if necessary, align the front end.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications
Ball Joint: Specifications
Ball Joint Deflection
Lower ...................................................................................................................................................
........................................ 0-0.8 mm (0-0.032 inch) Upper ..................................................................
......................................................................................................................... 0-0.2 mm (0-0.008
inch)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Page 6945
Ball Joint: Testing and Inspection
Ball Joint Inspection
1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. For additional information,
refer to Vehicle/Testing and Inspection.
2. NOTE: In order to obtain an accurate measurement, the suspension must be in full rebound with
the weight of the vehicle supported by the frame.
Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position.
3. Inspect the ball joint and ball joint boot for damage.
^ If the ball joint or ball joint boot is damaged, install a new ball joint as necessary.
NOTE: Carry out Steps 4-6 to inspect the lower ball joint. Carry out Steps 7-9 to inspect the upper
ball joint.
4. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or
suspension components while checking for relative
movement or suspension damage can occur. The use of tools or equipment will also create relative
movement that may not exist when using hand force. Relative movement must be measured using
hand force only.
NOTE: The weight of the wheel and tire assembly must be overcome to obtain an accurate
measurement on the dial indicator.
Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on
the wheel and tire assembly by hand. Note any relative vertical movement between the wheel
knuckle and lower arm at the lower ball joint. ^
If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
^ If relative movement is found, continue with Step 5.
5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close
as possible with the vertical axis (center line) of
the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the
lower control arm and the wheel knuckle or ball joint stud.
6. Measure the ball joint deflection while an assistant pushes up and pulls down on the wheel and
tire assembly, by hand.
^ If the deflection exceeds the specification, a new ball joint must be installed.
^ If the deflection meets the specification, continue with the procedure.
7. CAUTION: Do not use any tools or equipment to move the wheel and tire assembly or
suspension components while checking for relative
movement or suspension damage can occur. The use of tools or equipment will also create relative
movement that may not exist when using hand force. Relative movement must be measured using
hand force only.
Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on
the upper control arm by hand. Note any relative vertical movement between the wheel knuckle
and upper arm at the upper ball joint.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Page 6946
^ If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
^ If relative movement is found, continue with Step 8.
8. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close
as possible with the vertical axis of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the
upper control arm and the wheel knuckle or ball joint stud. ^
If the deflection meets the specification, no further action is required.
9. Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper
control arm, by hand.
^ If the deflection exceeds the specification, a new ball joint must be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front
Control Arm: Service and Repair Front
Lower Arm
Lower Arm
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6951
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6952
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a
level, static ground position (curb height).
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 3. Remove and discard the lower ball joint nut.
^ To install, tighten to 150 Nm (111 ft. lbs.)
4. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle.
5. Remove and discard the stabilizer bar link nut.
^ To install, tighten to 35 Nm (26 ft. lbs.) at curb height.
6. Remove the stabilizer bar link assembly. 7. Remove and discard the shock absorber lower bolt
and flag nut and bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6953
^ To install, tighten to 350 Nm (258 ft. lbs.) at curb height.
8. Remove and discard the lower arm forward nut and bolt.
^ To install, tighten to 400 Nm (296 ft. lbs.) at curb height.
9. Remove the lower arm rearward nut and bolt and the lower control arm.
^ Discard the nut and bolt.
^ To install, tighten to 200 Nm (148 ft. lbs.) at curb height.
10. CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the
suspension until the distance between the
center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb
height).
To install, reverse the removal procedure. ^
Check and, if necessary, align the front end.
Upper Arm
Upper Arm
Special Tool(s)
Removal and Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6954
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a
level, static ground position (curb height).
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 3. Using a suitable jack support the lower control arm near the
lower ball joint. 4. Remove and discard the upper ball joint nut.
^ To install, tighten to 55 Nm (41 ft. lbs.)
5. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
6. Using a plastic tie strap, support the suspension at the wheel knuckle.
7. Remove the 2 upper arm bolts and flag nuts and the upper arm.
^ To install, tighten to 150 Nm (111 ft. lbs.) at curb height.
8. CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the
suspension until the distance between the
center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb
height).
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6955
^ Check and, if necessary, align the front end.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6956
Control Arm: Service and Repair Rear
Upper Arm
Upper Arm
Upper Arm
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in when removed.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a
level, static ground position (curb height).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6957
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 3. Position a suitable jack under the wheel knuckle and raise the
suspension until the distance between the center of the hub and the lip of the fender
is equal to the measurement taken in Step 1.
4. Remove and discard the upper arm outboard nut and bolt.
5. NOTE: The inboard nut that is installed at the assembly plant is a flag nut. This flag nut is used
to set and maintain the rear camber settings.
Discard the flag nut and install a non-flag nut to allow the rear camber to be adjusted.
Remove and discard the upper arm inboard bolt and flag nut and remove the upper arm.
Installation
1. Position the upper arm and install a new inboard bolt and non-flag nut.
^ Tighten to 250 Nm (185 ft. lbs.)
2. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of
the vehicle or wheel damage can
occur.
Install a new outboard bolt and nut with the bolt head toward the front of the vehicle. ^
Tighten to 275 Nm (203 ft. lbs.)
3. Lower the suspension and remove the jack. 4. Check and, if necessary, align the rear end.
Lower Arm
Lower Arm
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6958
Lower Arm
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in when removed.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a
level, static ground position (curb height).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front > Page 6959
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 3. Position a suitable jack under the wheel knuckle and raise the
suspension until the distance between the center of the hub and the lip of the fender
is equal to the measurement taken in Step 1.
4. Remove and discard the lower arm outboard bolt and flag nut. 5. Remove the stabilizer bar link
nut and grommet, stud and link assembly.
^ Discard the nut and grommet.
6. Lower the suspension and remove the jack. 7. Remove and discard the shock absorber lower
nut and bolt. 8. Remove and discard the lower arm inboard nut and bolt and remove the lower arm.
Installation
1. CAUTION: Do not tighten the lower arm inboard nut at this time.
Position the lower arm and install a new lower arm inboard bolt and nut.
2. CAUTION: Do not tighten the shock absorber lower nut at this time.
Position the lower arm and install a new shock absorber lower bolt and nut.
3. Position a suitable jack under the wheel knuckle and raise the suspension until the distance
between the center of the hub and the lip of the fender
is equal to the measurement taken in Step 1.
4. Install the stabilizer link assembly, the link stud and a new nut and grommet.
^ Tighten to 30 Nm (22 ft. lbs.)
5. Install a new lower arm outboard bolt and flag nut.
^ Tighten the bolt to 275 Nm (203 ft. lbs.)
6. Tighten the lower arm inboard bolt to 250 Nm (185 ft. lbs.) 7. Tighten the shock absorber lower
bolt to 275 Nm (203 ft. lbs.) 8. Lower the suspension and remove the jack.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System
Information > Service and Repair > Crossmember - 1B
Rear Cross-Member: Service and Repair Crossmember - 1B
CROSSMEMBER - 1B
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 crossmember bolts. 3.
Remove the 4 crossmember nuts.
- To install, tighten to 103 Nm (76 lb-ft).
4. Remove the 1B crossmember. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System
Information > Service and Repair > Crossmember - 1B > Page 6965
Rear Cross-Member: Service and Repair Transmission Support Crossmember
TRANSMISSION SUPPORT CROSSMEMBER
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 transfer case skid plate
bolts and remove the transfer case skid plate.
- To install, tighten to 15 Nm (11 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System
Information > Service and Repair > Crossmember - 1B > Page 6966
3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar.
Remove the heat shield bolt from the RH heat shield. To install, tighten to 18 Nm (13 lb-ft).
4. Remove the heat shield bolt from the LH heat shield.
- To install, tighten to 18 Nm (13 lb-ft).
5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts.
- To install, tighten to 90 Nm (66 lb-ft).
7. Remove the 6 transmission crossmember lower bolts.
- To install, tighten to 80 Nm (59 lb-ft).
8. NOTE: Tighten the nut side of the joint.
Remove the 2 upper nuts and 2 bolts from the transmission crossmember. To install, tighten to 143 Nm (105 lb-ft).
9. Remove the transmission crossmember. 10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 6970
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. Remove the wheel bearing and hub assembly. 2. Remove the wheel speed sensor harness
bracket bolt from the wheel knuckle.
^ To install, tighten to 8 Nm (71 inch lbs.)
3. Remove and discard the tie-rod end nut.
^ To install, tighten to 103 Nm (76 ft. lbs.)
4. CAUTION: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the tie-rod boot while installing the special tool.
Using the special tool, separate the tie-rod end from the wheel knuckle.
5. Remove and discard the lower ball joint nut.
^ To install, tighten to 150 Nm (111 ft. lbs.)
6. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the lower ball joint from the wheel knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 6971
7. Remove and discard the upper ball joint nut.
^ To install, tighten to 55 Nm (41 ft. lbs.)
8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint and remove the wheel knuckle.
9. To install, reverse the removal procedure.
^ Check and if necessary, align the front end.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair
Rear Knuckle: Service and Repair
Wheel Knuckle
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 6975
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in when removed.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a
level, static ground position (curb height).
2. If equipped, remove the wheel speed sensor bolt and position the sensor aside.
3. CAUTION: Do not loosen the halfshaft nut and washer until the wheel and tire are removed from
the vehicle. Wheel bearing damage
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 6976
will occur if the wheel bearing is unloaded with the weight of the vehicle applied.
NOTE: Apply the brake to keep the halfshaft from rotating.
Remove and discard the front wheel hub nut.
4. Remove the parking brake shoes.
5. CAUTION: Do not use a hammer to separate the halfshaft from the hub. Damage to the threads
and internal constant velocity (CV) joint
components can result.
Using the special tool, press the halfshaft from the hub.
6. Position a suitable jack under the wheel knuckle and raise the suspension until the distance
between the center of the hub and the lip of the fender
is equal to the measurement taken in Step 1.
7. Remove and discard the toe link outboard nut and bolt. 8. Remove and discard the upper arm
outboard nut and bolt. 9. Remove and discard the lower arm outboard nut and bolt.
10. Remove and discard the 3 wheel knuckle bolts and remove the wheel knuckle. 11. If a new
wheel knuckle is being installed, remove the wheel bearing and wheel hub.
Installation
1. Position the wheel knuckle and install 3 new wheel knuckle bolts.
^ Tighten to 275 Nm (203 ft. lbs.)
2. Install a new lower arm outboard bolt and flag nut.
^ Tighten to 275 Nm (203 ft. lbs.)
3. CAUTION: The upper arm outboard bolt must be installed with the bolt head toward the front of
the vehicle or wheel damage can
occur.
Install a new upper arm outboard bolt and nut with the bolt head toward the front of the vehicle. ^
Tighten to 275 Nm (203 ft. lbs.)
4. Position the toe link and install a new toe link outboard bolt and nut.
^ Tighten to 350 Nm (259 ft. lbs.)
5. Lower the suspension and remove the jack. 6. Install the parking brake shoes. 7. Position the
wheel speed sensor and install the bolt.
^ Tighten to 8 Nm (71 inch lbs.)
8. Using a suitable halfshaft installer tool, install the halfshaft.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 6977
9. NOTE: Have an assistant press the brake pedal to keep the axle from turning.
Install a new halfshaft nut and washer. ^
Tighten to 275 Nm (203 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Information > Service and Repair
Rear Knuckle Alignment Link: Service and Repair
Toe Link
Toe Link
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in when removed.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a
level, static ground position (curb height).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Information > Service and Repair > Page 6981
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 3. Position a suitable jack under the wheel knuckle and raise the
suspension until the distance between the center of the hub and the lip of the fender
is equal to the measurement taken in Step 1.
4. Index-mark the toe link cam bolt to the subframe.
5. Remove the toe link cam adjuster nut, cam adjuster and cam bolt.
^ Discard the nut.
6. Remove and discard the toe link outboard nut and bolt and remove the toe link.
Installation
1. Position the toe link and install a new outboard bolt and nut.
^ Tighten to 350 Nm (259 ft. lbs.)
2. NOTE: Do not tighten the cam adjuster nut at this time.
Install the toe link cam bolt, cam adjuster and a new nut.
3. NOTE: Make sure the cam bolt and the adjustment cam are seated between the offsets before
tightening the nut.
Align the index mark on the cam bolt with the index mark on the subframe and tighten the nut. ^
Tighten to 275 Nm (203 ft. lbs.)
4. Lower the suspension and remove the jack. 5. Check and, if necessary, adjust the rear toe.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Locations > Page 6986
C226
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front
Stabilizer Link: Service and Repair Front
Stabilizer Bar and Link
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove and discard the 2 stabilizer bar nuts and grommets.
^ To install, tighten to 35 Nm (26 ft. lbs.) at curb height.
3. Remove and discard the 2 stabilizer bar studs. 4. Remove the 2 stabilizer bar links.
5. NOTE: Inspect and clean the mating surfaces and the internal threads. Make sure all mating
surfaces are free of foreign material and remove any
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6992
thread locking compound from the internal threads.
NOTE: Rotate the stabilizer bar and pull outward to remove.
Remove the 4 stabilizer bar bracket bolts and the stabilizer bar, and the brackets and bushings. ^
Discard the bolts.
^ To install, tighten to 55 Nm (41 ft. lbs.) at curb height.
6. NOTE: When installing the sway bar bushings onto the sway bar, match the groove in the
bushing to the upset on the sway bar.
NOTE: Inspect the stabilizer bar bushings for wear or damage. Install new bushings as necessary.
NOTE: Tighten LH side first.
Remove the 2 stabilizer bar bushings.
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6993
Stabilizer Link: Service and Repair Rear
Stabilizer Bar and Link - Explorer Sport Trac
Stabilizer Bar and Link - Explorer Sport Trac
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part, with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6994
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in when removed.
1. Remove both upper arms.
2. NOTE: Removal of the LH shock absorber lower bolt will allow more movement of the wheel
knuckle when installing the stabilizer bar.
Remove the LH shock absorber lower bolt.
3. Disconnect the purge solenoid electrical connector.
4. Unclip the wiring harness from the frame.
5. Remove the fuel tank filler pipe bracket bolt.
^ To install, tighten to 15 Nm (11 ft. lbs.)
6. Loosen the fuel tank filler pipe hose clamps and disconnect the hose.
^ To install, tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6995
7. Remove the stabilizer bar link nut and grommet, stud and link assembly.
^ Discard the nut and grommet.
^ To install, tighten to 30 Nm (22 ft. lbs.) at curb height.
8. Remove the wiring harness retainer caps from the stabilizer bar bracket studs.
9. Remove and discard the 4 stabilizer bar bracket nuts.
^ To install, tighten to 48 Nm (35 ft. lbs.)
10. Remove the 2 stabilizer bar brackets and the 2 stabilizer bar bushings. 11. Remove the 4
stabilizer bar bracket studs.
^ For the front studs, push the stud down and slide the stud toward the rear of the vehicle.
^ For the rear studs, push the stud down and slide the stud toward the front of the vehicle
12. Disconnect the fuel vapor line.
13. Unclip the fuel vapor line from the fuel tank and position aside.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front > Page 6996
14. CAUTION: When installing the stabilizer bar, care must be taken to avoid damage to the wiring
harness, fuel lines, fuel filler tube and
body.
CAUTION: Extreme care must be exercised when removing and installing the stabilizer bar on
vehicles equipped with rear air conditioning (A/C) and/or rear heating, or damage to the A/C lines
and rear heater hoses can occur.
With the aid of an assistant, remove the stabilizer bar from the LH side of the vehicle.
15. CAUTION: Before tightening the stabilizer bar link nuts, use a suitable jack to raise the
suspension until the distance between the center
of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height) of the
upper arm procedure.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement
Suspension Spring ( Coil / Leaf ): Removal and Replacement
Shock Absorber and Spring Assembly
Shock Absorber and Spring Assembly
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
1. Remove the lower arm. 2. Remove and discard the 3 shock absorber upper mount nuts and
remove the shock absorber and spring assembly.
^ To install, tighten to 30 Nm (22 ft. lbs.)
3. For additional information on the disassembly and assembly of the shock absorber and spring
assembly, refer to Shock Absorber and Spring
Assembly.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7001
Suspension Spring ( Coil / Leaf ): Overhaul
Front
Shock Absorber and Spring Assembly
Shock Absorber and Spring Assembly
Disassembly and Assembly
WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend
unassisted. Do not apply heat or flame to the shock absorbers during removal or component
servicing. Failure to follow these instructions may result in personal injury.
CAUTION: suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7002
1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor,
compress the spring until the tension is released from the shock absorber.
3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while
removing and installing the nut.
CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered
in the upper mount before tightening the nut.
Remove and discard the shock absorber rod nut. ^
To install, tighten to 65 Nm (48 ft. lbs.)
4. Remove the shock absorber. 5. Remove the washer and upper mount bushing. 6. Remove the
upper shock absorber mount. 7. Remove the dust boot. 8. Carefully release the spring compressor
and remove the coil spring.
9. NOTE: When installing the shock rod nut, make sure the shock rod and bushing are centered in
the upper mount before tightening the nut.
NOTE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are
aligned before tightening shock absorber rod nut.
To assemble, reverse the disassembly procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7003
Rear
Shock Absorber and Spring Assembly
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7004
Disassembly and Assembly
1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor,
compress the spring until the tension is released from the shock absorber.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7005
3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while
removing and installing the nut.
CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered
in the upper mount before tightening the nut.
Remove and discard the shock absorber rod nut. ^
To install, tighten to 65 Nm (48 ft. lbs.)
4. Remove the shock absorber. 5. Remove the shock absorber upper mount. 6. Remove the upper
mount bushing. 7. Carefully release the spring compressor and remove the coil spring.
8. NOTE: Make sure the upper shock mount stud, shock rod and shock lower bushing are aligned
before tightening the shock rod nut.
To assemble, reverse the disassembly procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement > Page 7006
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement
Suspension Strut / Shock Absorber: Removal and Replacement
Front Suspension
Shock Absorber and Spring Assembly
Special Tool(s)
Removal and Installation
WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend
unassisted. Do not apply heat or flame to the shock absorbers during removal or component
servicing. Failure to follow these instructions may result in personal injury.
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7011
retention of these parts.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a
level, static ground position (curb height).
2. Remove and discard the 3 shock absorber upper mount nuts.
^ To install, tighten to 30 Nm (22 ft. lbs.) at curb height.
3. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 4. Using a suitable jack, support the lower control arm near the
lower ball joint. 5. Remove and discard the stabilizer bar link nut and grommet and then remove the
stabilizer bar link assembly.
^ To install, tighten to 35 Nm (26 ft. lbs.) at curb height.
6. Remove the shock absorber lower bolt and flag nut.
^ Discard the lower shock bolt and flag nut.
^ To install, tighten to 350 Nm (258 ft. lbs.) at curb height.
7. Remove and discard the upper ball joint nut.
^ To install, tighten to 55 Nm (41 ft. lbs.)
8. CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to
the wheel knuckle can result.
CAUTION: Do not damage the ball joint boot while installing the special tool.
Using the special tool, separate the upper ball joint from the wheel knuckle.
9. While lowering the suspension, remove the shock and spring assembly.
10. CAUTION: Before tightening any suspension bushing fasteners, use a suitable jack to raise the
suspension until the distance between the
center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb
height).
To install, reverse the removal procedure.
Rear Suspension
Shock Absorber and Spring Assembly
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7012
Shock Absorber and Spring Assembly
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
1. Remove the lower arm. 2. Remove and discard the 3 shock absorber upper mount nuts and
remove the shock absorber and spring assembly.
^ To install, tighten to 30 Nm (22 ft. lbs.)
3. For additional information on the disassembly and assembly of the shock absorber and spring
assembly, refer to Shock Absorber and Spring
Assembly.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7013
Suspension Strut / Shock Absorber: Overhaul
Front
Shock Absorber and Spring Assembly
Shock Absorber and Spring Assembly
Disassembly and Assembly
WARNING: All vehicles are equipped with gas-pressurized shock absorbers which will extend
unassisted. Do not apply heat or flame to the shock absorbers during removal or component
servicing. Failure to follow these instructions may result in personal injury.
CAUTION: suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7014
1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor,
compress the spring until the tension is released from the shock absorber.
3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while
removing and installing the nut.
CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered
in the upper mount before tightening the nut.
Remove and discard the shock absorber rod nut. ^
To install, tighten to 65 Nm (48 ft. lbs.)
4. Remove the shock absorber. 5. Remove the washer and upper mount bushing. 6. Remove the
upper shock absorber mount. 7. Remove the dust boot. 8. Carefully release the spring compressor
and remove the coil spring.
9. NOTE: When installing the shock rod nut, make sure the shock rod and bushing are centered in
the upper mount before tightening the nut.
NOTE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are
aligned before tightening shock absorber rod nut.
To assemble, reverse the disassembly procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7015
Rear
Shock Absorber and Spring Assembly
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7016
Disassembly and Assembly
1. Remove the shock absorber and spring assembly. 2. Using a suitable spring compressor,
compress the spring until the tension is released from the shock absorber.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7017
3. CAUTION: Use the holding feature to prevent the shock absorber rod from turning while
removing and installing the nut.
CAUTION: When installing the shock rod nut, make sure the shock rod and bushing are centered
in the upper mount before tightening the nut.
Remove and discard the shock absorber rod nut. ^
To install, tighten to 65 Nm (48 ft. lbs.)
4. Remove the shock absorber. 5. Remove the shock absorber upper mount. 6. Remove the upper
mount bushing. 7. Carefully release the spring compressor and remove the coil spring.
8. NOTE: Make sure the upper shock mount stud, shock rod and shock lower bushing are aligned
before tightening the shock rod nut.
To assemble, reverse the disassembly procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement > Page 7018
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and
Repair
Trailing Arm: Service and Repair
Trailing Arm
Trailing Arm
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and
Repair > Page 7022
when removed.
1. Remove the toe link. 2. Remove the parking brake cable bracket bolt.
^ To install, tighten to 10 Nm (89 inch lbs.)
3. Remove and discard the trailing arm bolt.
^ To install, tighten to 300 Nm (222 ft. lbs.) at curb height.
4. Remove the 3 wheel knuckle bolts and the trailing arm.
^ Discard the bolts.
^ To install, tighten to 275 Nm (203 ft. lbs.)
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove and discard the halfshaft nut and washer.
^ To install, tighten to 250 Nm (184 ft. lbs.)
3. Using the special tool, separate the outboard CV joint from the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7027
4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^
Discard the bolts.
^ Support the caliper and anchor plate assembly using mechanic's wire.
^ To install, tighten to 165 Nm (122 ft. lbs.)
5. Remove the brake disc.
6. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it
from the wheel bearing and hub.
Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel
bearing and hub assembly. ^
To install, tighten to 18 Nm (13 ft. lbs.)
7. Remove the 3 bolts and the wheel bearing and hub assembly.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 ft. lbs.)
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7028
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts.
^ To install, tighten to 8 Nm (71 inch lbs.)
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front > Page 7029
4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To
install, reverse the removal procedure. 7. Install the wheel knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Axle Nut ...............................................................................................................................................
................................................ 250 Nm (184 ft. lbs.)
Remove and discard the halfshaft nut and washer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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.
CAUTION:
- A wheel chock should be used to prevent the vehicle from rolling and falling off the jack.
- Position the jack to avoid contact with the fuel tank.
The following offers general guidelines for vehicle jacking. Additionally, jack manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
jacking equipment before use.
Jacking Points
NOTE: Place a wheel chock diagonally opposite of the wheel to be raised.
The front jacking points are indicated by a cut-out in the frame, located behind the front tire and
wheel.
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle
cover and adjoining differential housing
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 7038
surface may occur if a floor jack or any lifting device is allowed to contact the cover at any point
where the cover joins the housing.
The rear jacking points are indicated by a cut-out in the frame in front of the rear tire and wheel.
LIFTING
Lifting Points
CAUTION: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
- Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
- Position the hoist adapters to avoid contact with the fuel tank.
- To avoid damage to the suspension, do not position the hoist adapters on the rear trailing arm
brackets.
NOTE: Explorer shown, Explorer Sport Trac similar.
The following offers general guidelines for vehicle lifting. Additionally, hoist manufacturers offer
their own operating precautions. Be sure to read and understand operating instructions for the
lifting equipment before use. Position the hoist directly under the frame rails.
Position the hoist directly under the frame rails.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Testing and Inspection
Tire Pressure Sensor: Testing and Inspection
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Smart Junction Box (SJB).
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Testing and Inspection > Page 7043
6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees)
from the valve stem. Press and release the test
button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the
tire pressure sensor has been recognized by the SJB.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and
the entire procedure must be repeated.
8. Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will be
verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and
document them on the applicable warranty claim.
NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed SJB.
10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry
out the SJB On-Demand Self Test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor can be removed and installed without removing the strap or the cradle.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Dismount the tire only as
instructed.
Remove the tire from the wheel.
2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor locking clip can occur.
Using a pocket screwdriver, or similar tool, remove the sensor locking clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor >
Page 7046
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor can occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle.
4. Remove the sensor.
Assembly
1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor
installation.
NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise
when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the
cradle and pushing the opposite end of the sensor down onto the cradle.
2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the
sensor locking clip cannot be fully inserted, then
the sensor may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor >
Page 7047
3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor >
Page 7048
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor >
Page 7049
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There
are several different strap kits available based on wheel diameter but all strap kits share the same
base part number.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. Remove the tire pressure monitoring system (TPMS) sensor.
2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and
gloves when removing the TPMS
band/strap. Failure to follow these instructions may result in personal injury.
Remove a factory installed strap in this sequence: 1
Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both
sides of the buckle approximately 25 mm (0.98 inch) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is
fully released from the worm gear.
^ Discard the strap.
3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle
and prying up.
Assembly
1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click"
noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of the sensor down onto the cradle.
2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to
remove the cradle adhesive strip residue.
NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the
valve stem.
Clean the area where the sensor and cradle are to be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor >
Page 7050
3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH
side when viewed from the curb side (beauty side)
of the wheel.
NOTE: The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel
drop well 180° from the valve stem.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is
positioned in the lowest spot possible for
correct sensor and cradle retention.
NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm
gear. ^
Tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor >
Page 7051
6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Testing and Inspection
Low Tire Pressure Indicator: Testing and Inspection
TPMS Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that
cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced.
TPMS Indicator Illuminates Continuously
NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the
vehicle to restore complete TPMS functionality before carrying out any diagnosis.
1. The TPMS indicator remains on continuously for this condition:
^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays
LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low.
When this condition exists, the tire pressure must be adjusted to the recommended cold pressure
as indicated on the vehicle certification label.
2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been
stationary for more than 30 minutes, it will be
necessary to wake up the sensors so they will transmit the latest tire pressure information to the
SJB.
If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the
TPMS sensors. 1
Turn the ignition switch to the ON position.
2 Adjust the air pressure in the LF tire.
3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool.
4 Repeat Steps 2 and 3 for the remaining tires.
5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to
Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures
TPMS Indicator Flashes
The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is
turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the
message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning.
GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures
2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is
illuminated when the instrument cluster has received no
signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related
Diagnostic Procedures
3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR
FAULT when the tire pressure monitoring system is
malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart.
See: Testing and Inspection/Symptom Related Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Testing and Inspection
Tire Pressure Sensor: Testing and Inspection
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Smart Junction Box (SJB).
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Testing and Inspection > Page 7059
6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees)
from the valve stem. Press and release the test
button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the
tire pressure sensor has been recognized by the SJB.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and
the entire procedure must be repeated.
8. Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will be
verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and
document them on the applicable warranty claim.
NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed SJB.
10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry
out the SJB On-Demand Self Test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor can be removed and installed without removing the strap or the cradle.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Dismount the tire only as
instructed.
Remove the tire from the wheel.
2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor locking clip can occur.
Using a pocket screwdriver, or similar tool, remove the sensor locking clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7062
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor can occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle.
4. Remove the sensor.
Assembly
1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor
installation.
NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise
when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the
cradle and pushing the opposite end of the sensor down onto the cradle.
2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the
sensor locking clip cannot be fully inserted, then
the sensor may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7063
3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7064
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7065
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There
are several different strap kits available based on wheel diameter but all strap kits share the same
base part number.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. Remove the tire pressure monitoring system (TPMS) sensor.
2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and
gloves when removing the TPMS
band/strap. Failure to follow these instructions may result in personal injury.
Remove a factory installed strap in this sequence: 1
Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both
sides of the buckle approximately 25 mm (0.98 inch) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is
fully released from the worm gear.
^ Discard the strap.
3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle
and prying up.
Assembly
1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click"
noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of the sensor down onto the cradle.
2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to
remove the cradle adhesive strip residue.
NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the
valve stem.
Clean the area where the sensor and cradle are to be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7066
3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH
side when viewed from the curb side (beauty side)
of the wheel.
NOTE: The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel
drop well 180° from the valve stem.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is
positioned in the lowest spot possible for
correct sensor and cradle retention.
NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm
gear. ^
Tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 7067
6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns
Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7076
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7077
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7078
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7084
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7085
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 7086
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking
Wheels: Customer Interest Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page
7095
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
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds
Wheels: Customer Interest Wheels/Tires - Popping/Snapping Noise At Low Speeds
TSB 09-11-2
06/15/09
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEED BELOW 10 MPH (16 KM/H)
FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer
LINCOLN: 2007-2008 MKX
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 09-4-3 to update the vehicle model years.
ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008
and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels
may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at
speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that
attaches to the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual
(WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds >
Page 7100
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft(R) Silicone Spray
Lubricant with an extension nozzle. (Figures 1 and 2)
4. Clean any excess lubricant off the wheel with a soft cloth.
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
091102A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace One Wheel
and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091102B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace Two
Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091102C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low Speeds >
Page 7101
MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire
Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
091102D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive,
Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning
Wheels: Customer Interest Wheels/Tires - Popping Noise From Wheels When Turning
TSB 07-23-4
11/26/07
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEEDS BELOW 10 MPH (16KM/H)
FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 07-19-6 to update the vehicle lines.
ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to
8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may
exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds
lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to
the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel
and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning >
Page 7106
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension
nozzle. (Figures 1 and 2)
NOTE
NEW WHEELS WILL NOT REQUIRE LUBRICATION.
4. Clean any excess lubricate off the wheel with a soft cloth.
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
072304A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining
Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance
Wheel Assembly (Do Not Use With 1007A, 1007A1)
072304B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two
Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
072304C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels When Turning >
Page 7107
Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS,
Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
072304D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking
Wheels: Customer Interest Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking
TSB 07-12-2
06/25/07
16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch
wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like
spider webs.
ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection.
SERVICE PROCEDURE
Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to
Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of
affected wheel in Figure 1.
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
071202A 2006-2007 Explorer, 2007 0.5 Hr.
Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking > Page
7112
071202B 2006-2007 Explorer, 2007 0.7 Hr.
Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202C 2006-2007 Explorer, 2007 1.0 Hr.
Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202D 2006-2007 Explorer, 2007 1.2 Hrs.
Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat
Cracking
Wheels: All Technical Service Bulletins Wheels - 17 Inch Polished Wheel Clearcoat Cracking
TSB 09-14-1
07/27/09
17 INCH BRIGHT MACHINED WHEEL - CORROSION AND ETCHING
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles and
equipped with 17 inch aluminum wheels may exhibit the clear coat peeling off the wheel or cracks
in the clear coat that look like spider webs.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Please review the illustrations of an affected wheel. (Figures 1 and 2)
2. To service, replace only affected wheel or wheels. Refer to Workshop Manual, Section 204-04
for wheel removal and installation procedures
including tire pressure monitoring system (TPMS) sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat
Cracking > Page 7118
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
091401A 2006-2010 Explorer, 0.6 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace One (1) wheel Includes Time To Transfer
TPMS, And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091401B 2006-2010 Explorer, 0.8 Hr.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Two (2) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401C 2006-2010 Explorer, 1.1 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Three (3) Wheels Includes Time To
Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091401D 2006-2010 Explorer, 1.3 Hrs.
Mountaineer, 2007-2010 Explorer Sport Trac: Replace Four (4) Wheels Includes Time To Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 91
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low
Speeds
Wheels: All Technical Service Bulletins Wheels/Tires - Popping/Snapping Noise At Low Speeds
TSB 09-11-2
06/15/09
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEED BELOW 10 MPH (16 KM/H)
FORD: 2007-2008 Edge, Explorer Sport Trac, Explorer
LINCOLN: 2007-2008 MKX
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 09-4-3 to update the vehicle model years.
ISSUE Some 2007-2008 Explorer, Sport Trac, and Mountaineer vehicles built prior to 1/28/2008
and 2007-2008 Edge and MKX vehicles built prior to 8/18/2008 and equipped with 18 inch wheels
may exhibit a noise coming from the front or rear wheel(s) while turning the steering wheel at
speeds lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that
attaches to the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace the wheel(s) that have the noise with updated service parts. Refer to Workshop Manual
(WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low
Speeds > Page 7123
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft(R) Silicone Spray
Lubricant with an extension nozzle. (Figures 1 and 2)
4. Clean any excess lubricant off the wheel with a soft cloth.
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
091102A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace One Wheel
and Lubricate Remaining Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assembly (Do Not Use With 1007A, 1007A1)
091102B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX:
Replace Two
Wheels and Lubricate Remaining Two Wheels. Includes Test Drive, Transfer Tire Pressure Monitor
Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
091102C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 09-11-2 > Jun > 09 > Wheels/Tires - Popping/Snapping Noise At Low
Speeds > Page 7124
MKX: Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer Tire
Pressure Monitor Sensor (TPMS), Balance And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
091102D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge, MKX: Replace Four Wheels. Includes Test Drive,
Transfer Tire Pressure Monitor Sensor (TPMS), And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels
When Turning
Wheels: All Technical Service Bulletins Wheels/Tires - Popping Noise From Wheels When Turning
TSB 07-23-4
11/26/07
POPPING/SNAPPING NOISE - FRONT OR REAR 18 INCH WHEELS - TURNING AT SLOW
SPEEDS BELOW 10 MPH (16KM/H)
FORD: 2007 Edge 2007-2008 Explorer Sport Trac, Explorer
MERCURY: 2007-2008 Mountaineer
This article supersedes TSB 07-19-6 to update the vehicle lines.
ISSUE Some 2007-2008 Explorer, Explorer Sport Trac and Mountaineer vehicles built prior to
8/17/2007 and 2007 Edge vehicles built prior to 8/24/2007 and equipped with 18" wheels may
exhibit noise coming from the front or rear wheel(s) while turning the steering wheel at speeds
lower than 10 MPH (16 Km/h). The noise may be coming from the chrome cladding that attaches to
the rim.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
IF THE SOURCE OF NOISE IS NOT FROM THE WHEEL, FOLLOW NORMAL WORKSHOP
MANUAL PROCEDURES.
1. Verify the noise is coming from the wheel(s).
2. Replace wheel(s) with updated service parts for 18" Chrome (Bright) Clad Cast Aluminum wheel
and Satin Clad Cast Aluminum wheel(s). Refer to Workshop Manual (WSM), Section 204-04.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels
When Turning > Page 7129
3. Lubricate the remaining wheels at the outboard wheel flange, between the cladding and the
wheel inter[ace. Use Motorcraft Silicone Spray Lubricant and spray lubricant with an extension
nozzle. (Figures 1 and 2)
NOTE
NEW WHEELS WILL NOT REQUIRE LUBRICATION.
4. Clean any excess lubricate off the wheel with a soft cloth.
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
072304A 2007-2008 Explorer, 0.9 Hr.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace One Wheel and Lubricate Remaining
Three Wheels. Includes Test Drive, Transfer Tire Pressure Monitor Sensor (TPMS), And Balance
Wheel Assembly (Do Not Use With 1007A, 1007A1)
072304B 2007-2008 Explorer, 1.1 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Two Wheels and Lubricate Remaining Two
Wheels. Includes Test Drive, Transfer TPMS, And Balance Wheel Assemblies (Do Not Use With
1007A, 1007A1)
072304C 2007-2008 Explorer, 1.4 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge:
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 07-23-4 > Nov > 07 > Wheels/Tires - Popping Noise From Wheels
When Turning > Page 7130
Replace Three Wheels and Lubricate Remaining Wheel. Includes Test Drive, Transfer TPMS,
Balance And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
072304D 2007-2008 Explorer, 1.6 Hrs.
Explorer Sport Trac, Mountaineer, 2007 Edge: Replace Four Wheels. Includes Test Drive, Transfer
TPMS, And Balance Wheel Assemblies (Do Not Use With 1007A, 1007A1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 68
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking
Wheels: All Technical Service Bulletins Wheels - 16 Inch Wheel Clear Coat Peeling/Cracking
TSB 07-12-2
06/25/07
16 INCH BRIGHT MACHINED WHEEL-CORROSION AND ETCHING
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
ISSUE Some 2006-2007 Explorer and 2007 Explorer Sport Trac vehicles equipped with 16 inch
wheels may exhibit the clear coat peeling off the wheel or cracks in the clear coat that look like
spider webs.
ACTION Replace affected wheel or wheels with new wheels that have added corrosion protection.
SERVICE PROCEDURE
Please review illustration shown below. To service, replace only affected wheel or wheels. Refer to
Workshop Manual Section 204-04 for wheel removal and installation procedures. See example of
affected wheel in Figure 1.
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
071202A 2006-2007 Explorer, 2007 0.5 Hr.
Explorer Sport Trac: Replace One Wheel, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 07-12-2 > Jun > 07 > Wheels - 16 Inch Wheel Clear Coat
Peeling/Cracking > Page 7135
071202B 2006-2007 Explorer, 2007 0.7 Hr.
Explorer Sport Trac: Replace Two Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202C 2006-2007 Explorer, 2007 1.0 Hr.
Explorer Sport Trac: Replace Three Wheels, Includes Time To Transfer Tire Pressure Monitor
Sensor (TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1,
1552A, 1007D3)
071202D 2006-2007 Explorer, 2007 1.2 Hrs.
Explorer Sport Trac: Replace All Wheels, Includes Time To Transfer Tire Pressure Monitor Sensor
(TPMS), Balance New Tire and Wheel Assembly (Do Not Use With 1007A, 1007A1, 1552A,
1007D3)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1007 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set
Intake Manifold: All Technical Service Bulletins Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set
TSB 06-7-10
04/17/06
MIL ON WITH DTC P2004 THROUGH P2008, P151A, P2015, P2020 - 4.6L 3V
FORD: 2005-2006 Mustang 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
This article supersedes TSB 05-25-15 to update the vehicle model years.
ISSUE Some 2005-2006 Mustang GT, 2006 Explorer 4dr/Mountaineer and 2007 Explorer Sport
Trac vehicles may exhibit the malfunction indicator lamp (MIL) on, with diagnostic trouble codes
(DTCs) P2004 through P2008, P151A, P2015, and P2020. All of these codes are associated with
the charge motion control valve (CMCV), actuator motor, and/or linkage concerns.
ACTION Refer to the following Service Procedure to determine if a CMCV Actuator Kit should be
installed.
SERVICE PROCEDURE
1. Does the vehicle exhibit DTC P2004, P2005, P2006, and/or P2007 (stuck CMCV
motor/linkages)?
a. If so, visually inspect CMCV linkages to ensure they are free of interference from improper wire
routings or foreign objects. If there is interference, resolve interference as needed. If there is no
interference or disconnected/damaged wiring to CMCV actuator proceed to Step 2.
b. If not, proceed to Step 2.
2. Remove intake manifold from engine as outlined in the Workshop Manual, Section 303-01.
Position the intake manifold on a clean flat work surface, with bottom side up as shown in the
CMCV Actuator Kit instruction sheet. Take care to prevent debris from entering the runner ports.
CAUTION
DO NOT REST THE MANIFOLD ON THE INTAKE MANIFOLD FLANGE, AS IRREPARABLE
DAMAGE MAY OCCUR TO THE CMCV PLATES.
NOTE
VISUALLY INSPECT THAT ALL CMCV PLATES ARE INTACT. BENT PLATES OR OTHERWISE
DAMAGED COMPONENTS WILL REQUIRE ENTIRE MANIFOLD REPLACEMENT (REFER TO
FIGURE 1 IN CMCV ACTUATOR KIT INSTRUCTION SHEET).
3. Disconnect the CMCV linkages from actuator motor by removing the two (2) clips (Figure 1).
Discard clips.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 7141
4. Rotate each CMCV shaft (right hand and left hand) by hand, to verify that the system does not
stick or bind. The shafts should rotate freely and any sticking or binding will require replacement of
the entire intake manifold.
5. If the components inspected in Steps 1, 2, and 3 are OK, then replace CMCV actuator motor by
following procedure included in the service kit.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060710A 2005-2006 Mustang 4.6L 1.8 Hrs.
3V: Inspect CMCV plates, Replace Intake Manifold, Includes Time To Check For Diagnostic
Trouble Codes, Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A,
9531A, 9424A, 9926A, 12650D24, 12650D35)
060710B 2005-2006 Mustang 4.6L 1.7 Hrs
3V: Inspect CMCV plates, Replace CMCV, Includes Time To Check For Diagnostic Trouble Codes,
Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A, 9531A, 9424A,
9926A, 12650D24, 12650D35)
06071OC 2006 Explorer, 1.9 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace Intake Manifold
Includes Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do
Not Use With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 12650D24, 12650D35)
060710D 2006 Explorer, 1.8 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace CMCV, Includes
Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do Not Use
With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 1650D24, 12650D35)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 7142
DEALER CODING
CONDITION
BASIC PART NO. CODE
9G730 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 7148
4. Rotate each CMCV shaft (right hand and left hand) by hand, to verify that the system does not
stick or bind. The shafts should rotate freely and any sticking or binding will require replacement of
the entire intake manifold.
5. If the components inspected in Steps 1, 2, and 3 are OK, then replace CMCV actuator motor by
following procedure included in the service kit.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060710A 2005-2006 Mustang 4.6L 1.8 Hrs.
3V: Inspect CMCV plates, Replace Intake Manifold, Includes Time To Check For Diagnostic
Trouble Codes, Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A,
9531A, 9424A, 9926A, 12650D24, 12650D35)
060710B 2005-2006 Mustang 4.6L 1.7 Hrs
3V: Inspect CMCV plates, Replace CMCV, Includes Time To Check For Diagnostic Trouble Codes,
Remove and Install Intake Manifold (Do Not Use With 12650D, 9280A, 9424A, 9531A, 9424A,
9926A, 12650D24, 12650D35)
06071OC 2006 Explorer, 1.9 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace Intake Manifold
Includes Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do
Not Use With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 12650D24, 12650D35)
060710D 2006 Explorer, 1.8 Hrs.
Mountaineer 2007 Explorer Sport Trac 4.6L 3V: Inspect CMCV plates, Replace CMCV, Includes
Time To Check For Diagnostic Trouble Codes, Remove and Install Intake Manifold (Do Not Use
With 12650D, 9280A, 9424A, 9531A, 9424A, 9926A, 1650D24, 12650D35)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 06-7-10 > Apr > 06 > Engine - MIL ON/DTC's
P2000-P2008/P2015/P2020 Set > Page 7149
DEALER CODING
CONDITION
BASIC PART NO. CODE
9G730 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front
Wheel Bearing: Service and Repair Front
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with the
same part number or an equivalent part must be installed, if installation is necessary. Do not use a
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair. 2. Remove and discard the halfshaft nut and washer.
^ To install, tighten to 250 Nm (184 ft. lbs.)
3. Using the special tool, separate the outboard CV joint from the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7154
4. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^
Discard the bolts.
^ Support the caliper and anchor plate assembly using mechanic's wire.
^ To install, tighten to 165 Nm (122 ft. lbs.)
5. Remove the brake disc.
6. CAUTION: Inspect and if necessary, clean area around wheel speed sensor before removing it
from the wheel bearing and hub.
Remove the wheel speed sensor bolt and disconnect the wheel speed sensor from the wheel
bearing and hub assembly. ^
To install, tighten to 18 Nm (13 ft. lbs.)
7. Remove the 3 bolts and the wheel bearing and hub assembly.
^ Discard the bolts.
^ To install, tighten to 122 Nm (90 ft. lbs.)
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7155
Wheel Bearing: Service and Repair Rear
Wheel Bearing and Wheel Hub
Special Tool(s)
Removal and Installation
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
1. Remove the wheel knuckle. 2. Remove the 3 brake disc shield bolts.
^ To install, tighten to 8 Nm (71 inch lbs.)
3. Using the special tool and a suitable press, remove the wheel hub.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front > Page 7156
4. Remove the snap ring. 5. Using a suitable press and adapters, remove the wheel bearing. 6. To
install, reverse the removal procedure. 7. Install the wheel knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Axle Nut ...............................................................................................................................................
................................................ 250 Nm (184 ft. lbs.)
Remove and discard the halfshaft nut and washer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Lug Nuts
..........................................................................................................................................................
135 Nm (100 ft. lbs.) in a star pattern
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Special Tool(s)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the caliper, pads and anchor plate assembly aside. ^
Support the caliper and anchor plate assembly using mechanic's wire.
^ To install, tighten to 200 Nm (148 ft. lbs.)
3. Remove the brake disc. 4. Using the special tool, remove the wheel stud.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7166
Installation
1. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be
stripped.
NOTE: Do not use the wheel nut that came with the vehicle.
Install washers and a new wheel nut on the wheel stud and tighten the nut until the stud seats
against the flange. ^
Discard the wheel nut and washers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7167
Wheel Fastener: Service and Repair Rear
Wheel Studs
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7168
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital parts
and systems and their failure can result in major service expense. A new part with the same part
number must be installed if installation becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
CAUTION: Orientation of the suspension fasteners is important. Make sure the fasteners are
installed in the same direction as they were in when removed.
1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to
Maintenance/Service and Repair.
2. CAUTION: Care must be used when servicing rear brake components without disconnecting the
parking brake cable from the brake
caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking
brake cable end fittings can occur.
CAUTION: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the bolts and position the brake caliper aside. ^
Support the caliper using mechanic's wire.
3. Remove the brake disc.
4. Remove the parking brake shoe adjuster spring and adjuster.
5. CAUTION: The brake shield has an access hole knockout that must be removed to allow for the
removal of the wheel stud.
Using a suitable punch, remove the access hole cover from the brake shield.
6. NOTE: Make sure that the wheel stud is aligned with the recessed area of the wheel knuckle.
Using the special tool, press the wheel stud until it makes contact with the edge of the wheel
knuckle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 7169
7. Route the wheel stud through the access hole and discard the wheel stud.
Installation
1. Position the new wheel stud aligning the serrations in the wheel hub made by the original wheel
stud.
2. CAUTION: Do not use power tools to install the wheel stud. The serrations on the stud can be
stripped.
NOTE: Do not use the wheel nut that came with the vehicle.
Place flat washers over the outside end of the wheel stud and thread a standard wheel nut with the
flat side against the washers. Tighten the wheel nut until the wheel stud seats against the back side
of the wheel extension. ^
Discard the wheel nut and washers.
3. CAUTION: A plug must be installed in place of the knockout to prevent contamination to the
parking brake shoe assemblies.
Install a plug into the access hole on the brake shield.
4. Install the parking brake shoe adjuster and spring. 5. Install the brake disc. 6. Position the brake
caliper and install the bolts.
^ Tighten to 32 Nm (24 ft. lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and
Operation
Accumulator HVAC: Description and Operation
SUCTION ACCUMULATOR
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The suction accumulator is located at the RH rear of the engine compartment. The suction
accumulator is used to prevent residual liquid refrigerant from reaching the A/C compressor after
leaving the evaporator core. The suction accumulator allows the accumulated heavier liquid
refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. A desiccant
bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Suction Accumulator
Accumulator HVAC: Service and Repair Suction Accumulator
SUCTION ACCUMULATOR
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
All vehicles
1. Recover the refrigerant. 2. Remove the PCM. 3. Remove the low-side service port stem bracket
bolt.
- To install, tighten to 11 Nm (8 lb-ft).
4. Disconnect the A/C cycling switch electrical connector. 5. Remove the suction accumulator bolt.
- To install, tighten to 11 Nm (8 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Suction Accumulator > Page 7176
6. Remove the PCM bracket bolt.
7. Remove the PCM bracket nut and the PCM bracket. 8. Remove the suction accumulator stud.
- To install, tighten to 11 Nm (8 lb-ft).
4.6L vehicles
9. Remove the suction accumulator-to-compressor line bracket nut at the condenser-to-evaporator
line bracket.
All vehicles
10. Remove the 2 suction accumulator fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
11. Remove the suction accumulator bracket bolt and suction accumulator. 12. To install, reverse
the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
13. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Suction Accumulator > Page 7177
Accumulator HVAC: Service and Repair Suction Accumulator to Compressor Line
SUCTION ACCUMULATOR TO COMPRESSOR LINE
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system, except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
1. Recover the refrigerant. 2. Remove the suction accumulator outlet fitting nut.
- To install, tighten to 8 Nm (71 lb-in).
3. Disconnect the auxiliary evaporator outlet line fitting.
- Discard the O-ring seals.
4. Remove the suction accumulator-to-compressor line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
5. Remove the suction accumulator-to-compressor line middle fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Suction Accumulator > Page 7178
6. Remove the rear suction accumulator-to-compressor line.
- Discard the O-ring seal.
7. NOTE: The compressor suction fitting nut can be accessed through the RH wheel well.
Remove the compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).
8. Remove the front suction accumulator-to-compressor line. 9. To install, reverse the removal
procedure.
- Install new O-ring seals and a new gasket seal.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
10. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Suction Accumulator > Page 7179
Accumulator HVAC: Service and Repair Suction Accumulator to Evaporator Line
SUCTION ACCUMULATOR TO EVAPORATOR LINE
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system, except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
All vehicles
1. Remove the suction accumulator. 2. Remove the powertrain control module (PCM) and PCM
bracket. 3. Remove the A/C line bracket nut at the dash panel and remove the A/C line bracket.
- To install, tighten to 6 Nm (53 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Suction Accumulator > Page 7180
4. Remove the ground strap bolt at the dash panel. 5. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.
Vehicles with 4.0L engine
6. Disconnect he evaporative emissions return line fitting at the intake manifold.
7. Remove the fuel line bracket bolt at the rear of the RH valve cover.
8. Remove the wire harness bolt at the rear of the RH cylinder head.
All vehicles
9. Remove the suction accumulator-to-evaporator line.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Suction Accumulator > Page 7181
10. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations >
Page 7185
C2208
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator, Driver
Air Door Actuator / Motor: Locations Temperature Blend Door Actuator, Driver
View 151-10 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator, Driver > Page 7191
View 151-11 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Temperature Blend Door Actuator, Driver > Page 7192
View 151-11 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Temperature Blend Door Actuator, Driver
C2091
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Temperature Blend Door Actuator, Driver > Page 7195
C2092
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH
Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - LH
TEMPERATURE BLEND DOOR ACTUATOR - LH
Removal and Installation
1. Remove the LH floor console finish panel. 2. Position the in-vehicle temperature sensor aspirator
hose away from the LH temperature blend door actuator. 3. Remove the 3 LH temperature blend
door actuator screws. 4. Disconnect the LH temperature blend door actuator electrical connector.
5. Remove the LH temperature blend door actuator. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7198
Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator - RH, EATC
TEMPERATURE BLEND DOOR ACTUATOR - RH, EATC
Removal and Installation
1. Remove the RH floor console finish panel. 2. Lower the glove compartment. 3. Disconnect the
RH temperature blend door actuator electrical connector. 4. Remove the 3 RH temperature blend
door actuator screws. 5. Remove the RH temperature blend door actuator. 6. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7199
Air Door Actuator / Motor: Service and Repair Vacuum Control Motor
Air Inlet Door
VACUUM CONTROL MOTOR - AIR INLET DOOR
Removal and Installation
1. Lower the glove compartment.
2. Remove the screws and the heater core and evaporator core housing support brace. 3.
Disconnect the air inlet door vacuum control motor vacuum connector. 4. Remove the 2 air inlet
door vacuum control motor screws. 5. Rotate the air inlet door vacuum control motor until it clears
the retaining arm and remove the vacuum control motor. 6. To install, reverse the removal
procedure.
Defroster Door
VACUUM CONTROL MOTOR - DEFROSTER DOOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7200
Removal and Installation
1. Remove the audio unit. 2. Remove the lower steering column cover.
3. Remove the 3 center panel duct screws and position the center panel duct aside.
4. Remove the 2 plenum chamber screws. 5. Disconnect the defrost door vacuum control motor
vacuum connector. 6. Remove the 2 defrost door vacuum control motor screws.
7. NOTE: The plenum chamber must be slightly repositioned to allow the defrost door vacuum
control motor to be rotated far enough to clear the
retaining arm.
Rotate the defrost door vacuum control motor until it clears the retaining arm and remove the
defrost door vacuum control motor.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7201
Floor Door
VACUUM CONTROL MOTOR - FLOOR DOOR
Removal and Installation
1. Remove the center instrument panel finish panel. 2. Remove the shield screw. 3. Remove the
shield. 4. Lower the glove compartment. 5. Disconnect the floor door vacuum control motor vacuum
connector.
6. Detach the instrument panel harness pin-type retainer and position the harness aside. 7.
Remove the 2 floor door vacuum control motor screws.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7202
8. Remove the RH floor console finish panel.
9. NOTE: The retaining arm must be slightly deflected away from the vacuum control motor arm to
provide clearance.
Partially actuate and rotate the floor door vacuum control motor until it clears the retaining arm and
remove the vacuum control motor.
10. To install, reverse the removal procedure.
Panel Door
VACUUM CONTROL MOTOR - PANEL DOOR
Removal and Installation
1. Remove the audio unit. 2. Lower the glove compartment.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7203
3. Remove the 3 center panel duct screws and position the center panel duct aside.
4. Remove the 2 plenum chamber screws. 5. Disconnect the panel door vacuum control motor
vacuum connector. 6. Remove the 2 panel door vacuum control motor screws.
7. NOTE: The plenum chamber must be slightly repositioned to allow the panel door vacuum
control motor to be rotated far enough to clear the
retaining arm.
Rotate the panel door vacuum control motor until it clears the retaining arm and remove the panel
door vacuum control motor.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7204
Air Door Actuator / Motor: Service and Repair Auxiliary Mode Door Actuator
AUXILIARY MODE DOOR ACTUATOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH quarter trim panel. 3.
Remove the 2 auxiliary line floorpan bracket nuts.
- To install, tighten to 8 Nm (71 lb-in).
4. Remove the 2 auxiliary heater core and evaporator core housing bolts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7205
- To install, tighten to 6 Nm (53 lb-in).
5. Remove the auxiliary heater core and evaporator core housing nut.
- To install, tighten to 6 Nm (53 lb-in).
6. Disconnect the auxiliary harness electrical connector. 7. Disconnect the auxiliary mode door
actuator electrical connector. 8. Remove the 3 auxiliary mode door actuator screws. 9. Remove the
auxiliary mode door actuator.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7206
Air Door Actuator / Motor: Service and Repair Auxiliary Temperature Blend Door Actuator
AUXILIARY TEMPERATURE BLEND DOOR ACTUATOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH quarter trim panel. 3.
Remove the 2 auxiliary line floorpan bracket nuts.
- To install, tighten to 8 Nm (71 lb-in).
4. Remove the 2 auxiliary heater core and evaporator core housing bolts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Temperature Blend Door Actuator - LH > Page 7207
- To install, tighten to 6 Nm (53 lb-in).
5. Remove auxiliary heater core and evaporator core housing nut.
- To install, tighten to 6 Nm (53 lb-in).
6. Disconnect the auxiliary harness electrical connector. 7. Disconnect the auxiliary temperature
blend door actuator electrical connector. 8. Remove the 3 auxiliary temperature blend door actuator
screws. 9. Remove the auxiliary temperature blend door actuator.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair
Air Duct: Service and Repair
AIR INLET DUCT
Removal and Installation
1. Remove the heater core and evaporator core housing. 2. Remove the air inlet duct.
1 Remove the support bracket screw.
2 Disconnect the air inlet door vacuum control motor vacuum connector.
3 Remove the 3 air inlet duct screws.
4 Remove the air inlet duct.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7214
C132
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 7215
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
Removal and Installation
Mountaineer
1. Remove the radiator grille.
2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air
deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator
support.
All vehicles
4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air
temperature sensor. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 07-12-6 > Jun > 07 > A/C - Front Blower Motor Whistling Noise
Blower Motor: Customer Interest A/C - Front Blower Motor Whistling Noise
TSB 07-12-6
06/25/07
FRONT BLOWER MOTOR WHISTLE NOISE - VEHICLES BUILT ON OR BEFORE 06/7/2007
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer, Mountaineer and 2007 Sport Trac vehicles built on or before
6/7/2007 may exhibit a whistling noise from the instrument panel coming from the front blower
motor. Typically, the noise will occur when the blower motor is set to high speed, the air
recirculation is deactivated (fresh air mode) and when the climate control temperature is set to cold.
The noise is due to an air gap in the blower motor housing at the electrical connector.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To service, first verify if the noise is coming from this location. If the noise is coming from this
location, seal the air gap. Refer to the following Concern Verification method and Repair
Procedure.
Concern Verification
1. Locate the blower motor behind the dash panel on the right hand side.
2. With the front blower motor running, place an object (such as a shop-towel) on top of the area
behind the motor connector. There should be a change in the noise frequency, or the noise may
completely stop, but will return after clearing the area behind the electrical connector.
Repair Procedure
NOTE
IT IS NOT NECESSARY TO REMOVE THE MOTOR FROM THE INSTRUMENT PANEL TO
PERFORM THIS PROCEDURE.
1. Lower the glove box compartment.
2. Disconnect the motor's electrical connector.
3. Apply Motorcraft® Clear Silicone Rubber (TA-32) using a fine pointed nozzle in the area behind
the electrical connector (Figure 1).
4. Reconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 07-12-6 > Jun > 07 > A/C - Front Blower Motor Whistling Noise > Page
7224
5. Reassemble.
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
071206A 2006-2007 0.3 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac: Apply Silicone Following Service Procedure
Includes Time To Verify Concern
DEALER CODING
CONDITION
BASIC PART NO. CODE
19805 12
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 07-12-6 > Jun > 07 > A/C - Front Blower Motor Whistling
Noise
Blower Motor: All Technical Service Bulletins A/C - Front Blower Motor Whistling Noise
TSB 07-12-6
06/25/07
FRONT BLOWER MOTOR WHISTLE NOISE - VEHICLES BUILT ON OR BEFORE 06/7/2007
FORD: 2006-2007 Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Mountaineer
ISSUE Some 2006-2007 Explorer, Mountaineer and 2007 Sport Trac vehicles built on or before
6/7/2007 may exhibit a whistling noise from the instrument panel coming from the front blower
motor. Typically, the noise will occur when the blower motor is set to high speed, the air
recirculation is deactivated (fresh air mode) and when the climate control temperature is set to cold.
The noise is due to an air gap in the blower motor housing at the electrical connector.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
To service, first verify if the noise is coming from this location. If the noise is coming from this
location, seal the air gap. Refer to the following Concern Verification method and Repair
Procedure.
Concern Verification
1. Locate the blower motor behind the dash panel on the right hand side.
2. With the front blower motor running, place an object (such as a shop-towel) on top of the area
behind the motor connector. There should be a change in the noise frequency, or the noise may
completely stop, but will return after clearing the area behind the electrical connector.
Repair Procedure
NOTE
IT IS NOT NECESSARY TO REMOVE THE MOTOR FROM THE INSTRUMENT PANEL TO
PERFORM THIS PROCEDURE.
1. Lower the glove box compartment.
2. Disconnect the motor's electrical connector.
3. Apply Motorcraft® Clear Silicone Rubber (TA-32) using a fine pointed nozzle in the area behind
the electrical connector (Figure 1).
4. Reconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 07-12-6 > Jun > 07 > A/C - Front Blower Motor Whistling
Noise > Page 7230
5. Reassemble.
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
071206A 2006-2007 0.3 Hr.
Explorer/Mountaineer, 2007 Explorer Sport Trac: Apply Silicone Following Service Procedure
Includes Time To Verify Concern
DEALER CODING
CONDITION
BASIC PART NO. CODE
19805 12
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Page 7231
Blower Motor: Locations
View 151-10 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Page 7232
View 151-11 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions
Blower Motor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7235
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7236
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7237
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7238
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7239
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7240
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7241
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7242
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7243
Blower Motor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7244
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7245
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7246
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7247
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7248
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7249
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7250
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7251
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7252
C2004
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor
Blower Motor: Service and Repair Blower Motor
BLOWER MOTOR
Removal and Installation
1. Remove the vacuum reservoir screw. 2. Position the vacuum reservoir aside. 3. Disconnect the
blower motor electrical connector. 4. Remove the 3 blower motor screws. 5. Remove the blower
motor.
6. Remove the blower motor wheel from the blower motor.
1 Remove the push clip.
2 Remove the blower motor wheel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor > Page 7255
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor > Page 7256
Blower Motor: Service and Repair Auxiliary Blower Motor
AUXILIARY BLOWER MOTOR
Removal and Installation
1. Remove the bolts and the rear cargo management cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor > Page 7257
2. Remove the rear cargo management system.
1 Remove the screw.
2 Remove the pin-type retainer.
3 Remove the rear cargo management system.
3. Remove the access panel. 4. Remove the vent tube. 5. Disconnect the blower motor electrical
connector. 6. Remove the 3 blower motor screws. 7. Remove the blower motor. 8. Remove the
blower motor retainer. 9. Remove the blower motor wheel.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay 1 > Page 7262
View 151-10 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Page 7263
C2017
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Blower Motor Relay 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Inspection > Blower Motor Relay 1 > Page 7266
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
View 151-10 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 7270
C293
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Blower Motor Resistor
Blower Motor Resistor: Service and Repair Blower Motor Resistor
BLOWER MOTOR RESISTOR
Removal and Installation
1. Remove the 2 four wheel drive (4WD) control module screws. 2. Disconnect the blower motor
resistor electrical connector. 3. Remove the 2 blower motor resistor screws. 4. Remove the blower
motor resistor. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Blower Motor Resistor > Page 7273
Blower Motor Resistor: Service and Repair Auxiliary Blower Motor Resistor
AUXILIARY BLOWER MOTOR RESISTOR
Removal and Installation
1. Remove the switch bezel. 2. Disconnect the power lock switch electrical connector. 3. Remove
the access panel. 4. Disconnect the auxiliary blower motor resistor electrical connector. 5. Remove
the 2 auxiliary blower motor resistor screws. 6. Remove the auxiliary blower motor resistor. 7. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations
View 151-11 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 7277
C271
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Page 7278
Blower Motor Switch: Service and Repair
BLOWER MOTOR SPEED CONTROL
Removal and Installation
1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3.
Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
This vehicle is not factory equipped with a Cabin Air Filter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7285
C233
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 7286
Cabin Temperature Sensor / Switch: Service and Repair
IN-VEHICLE TEMPERATURE SENSOR
Removal and Installation
1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Item.......................................................................................................................................................
..............................................................Specification
Magnetic Clutch
Air gap clearance..................................................................................................................................
.................................. 0.35-0.65 mm (0.014-0.026 in)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7291
Compressor Clutch: Adjustments
AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT
1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C
clutch pulley. 2. Remove the clutch plate. Add or remove spacers between the clutch plate hub and
the compressor shaft until the clearance is within specification.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7292
Compressor Clutch: Service and Repair
CLUTCH AND CLUTCH FIELD COIL
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7293
Removal
All vehicles 1. Remove the A/C compressor.
2. Remove the A/C clutch disc and hub bolt.
1 Hold the A/C clutch disc and hub with the special tool.
2 Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub. 4. Remove the A/C compressor pulley snap ring.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7294
5. Remove the A/C compressor pulley.
1 Install the special tool.
2 Remove the A/C compressor pulley.
FS18 compressors only
6. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
Remove the A/C clutch field coil. 1
Install the special tool.
2 Install the special tool.
3 Remove the A/C clutch field coil.
FS20 compressors only 7. Remove the A/C clutch field coil snap ring. 8. Remove the A/C clutch
field coil.
Installation
NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless
obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub
and A/C compressor pulley must be installed together. Otherwise, each component can be
installed individually where needed.
All vehicles 1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch
field coil for damage.
- Inspect for physical damage, including cracked or melted components or discoloration due to
excessive heat.
- Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor
pulley that is more than fingernail depth.
- Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
FS18 compressors only
3. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
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 412-065 on the special tool 412-078.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7295
4 Use the special tool to install the A/C clutch field coil.
FS20 compressors only 4. Install the A/C clutch field coil. 5. Install the A/C clutch field coil snap
ring.
All vehicles
6. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly
aligned during installation.
Install the A/C clutch pulley.
7. Install the A/C clutch pulley snap ring with the bevel side out. 8. Place one nominal thickness
A/C clutch disc and hub spacer inside the clutch hub spline opening. 9. Install the A/C clutch disc
and hub assembly.
10. Install the A/C clutch disc and hub bolt.
1 Hold the A/C clutch disc and hub with the special tool.
2 Install the A/C clutch disc and hub bolt. Tighten to 13 Nm (10 lb-ft).
11. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 12. Install
the A/C compressor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7299
C1110
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7300
Compressor Clutch Coil: Service and Repair
CLUTCH AND CLUTCH FIELD COIL
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7301
Removal
All vehicles
1. Remove the A/C compressor.
2. Remove the A/C clutch disc and hub bolt.
1 Hold the A/C clutch disc and hub with the special tool.
2 Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub. 4. Remove the A/C compressor pulley snap ring.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7302
FS18 compressors only
5. Remove the A/C compressor pulley.
1 Install the special tool.
2 Remove the A/C compressor pulley.
FS 20 compressors only
6. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Remove the
A/C clutch field coil.
1 Install the special tool.
2 Install the special tool.
3 Remove the A/C clutch field coil.
7. Remove the A/C clutch field coil snap ring. 8. Remove the A/C clutch field coil.
Installation
NOTE: If installing a new A/C compressor, the A/C clutch components should be reused unless
obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub
and A/C compressor pulley must be installed together. Otherwise, each component can be
installed individually where needed.
All vehicles
1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for
damage.
- Inspect for physical damage, including cracked or melted components or discoloration due to
excessive heat.
- Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor
pulley that is more than fingernail depth.
- Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
FS18 compressors only
3. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
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 412-065 on the special tool 412-078.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations > Page 7303
4 Use the special tool to install the A/C clutch field coil.
FS20 compressors only
4. Install the A/C clutch field coil. 5. Install the A/C clutch field coil snap ring.
All vehicles
6. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly
aligned during installation. Install the A/C clutch
pulley.
7. Install the A/C clutch pulley snap ring with the bevel side out. 8. Place one nominal thickness
A/C clutch disc and hub spacer inside the clutch hub spline opening. 9. Install the A/C clutch disc
and hub assembly.
10. Install the A/C clutch disc and hub bolt.
1 Hold the A/C clutch disc and hub with the special tool.
2 Install the A/C clutch disc and hub bolt.
- Tighten to 13 Nm (10 lb-ft).
11. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 12. Install
the A/C compressor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7307
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR)
NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to
monitor the A/CCR output.
The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch
or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives
a signal indicating that A/C is requested. For some applications, this message is sent through the
communications network. When A/C is requested, the PCM checks other A/C related inputs that
are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C
operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle
position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to
the A/CCR.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 7308
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation
Condenser HVAC: Description and Operation
CONDENSER CORE
NOTE: Installation of a new 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 is an aluminum fin and tube design heat exchanger, located in front of the vehicle
radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract
heat and by condensing gas to liquid refrigerant as it is cooled.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 7312
Condenser HVAC: Service and Repair
CONDENSER CORE
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
1. Recover the refrigerant. 2. Remove the air cleaner. 3. Remove the 2 coolant expansion tank
bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Operation > Page 7313
4. Disconnect the A/C pressure transducer electrical connector. 5. Remove the condenser inlet
fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
6. Remove the condenser outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
7. Detach the 2 compressor-to-condenser discharge line clips. 8. Remove the 2 cooling module
bolts and position the cooling module rearward.
- To install, tighten to 12 Nm (9 lb-ft).
9. Remove the upper radiator air deflector.
10. Remove the 2 condenser core bolts.
- To install, tighten to 12 Nm (9 lb-ft).
11. Remove the condenser core. 12. Remove the 2 condenser air deflectors. 13. To install, reverse
the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
14. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions
Control Assembly: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7319
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7320
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7321
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7322
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7323
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7324
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7325
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7326
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7327
Control Assembly: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7328
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7329
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7330
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7331
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7332
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7333
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7334
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7335
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7336
Control Assembly: Connector Views
C294A
C294B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions > Page 7337
C294C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Control Components
Control Assembly: Description and Operation Control Components
CONTROL COMPONENTS
MANUAL CLIMATE CONTROL
The manual climate control components are used to select:
- air inlet source (outside or recirculated).
- blower motor speed.
- discharge air temperature (temperature blend).
- discharge air location (defrost, panel, floor).
- A/C compressor operation.
Control System Inputs
The climate control assembly has 3 system control inputs.
Climate Control Assembly The climate control assembly integrates the temperature control switch,
A/C request button and rear defog switch into a single unit.
The temperature control switch setting determines air temperature. Temperature selection is
accomplished with a potentiometer (temperature control switch) connected to the temperature
blend door actuator. Movement of the temperature control switch from COOL (blue) to WARM (red)
causes a corresponding movement of the temperature blend door and determines the air discharge
temperature that the air distribution system will maintain. The temperature control switch is an
integral part of the manual climate control assembly and a new one cannot be separately installed.
The A/C request switch determines A/C compressor operation, except when the function selector
switch is in the OFF, MAX, DEFROST or FLOOR/DEFROST positions. The A/C request switch is
an integral part of the manual climate control assembly and a new one cannot be separately
installed.
The rear defog button signals activation of the heated backlight and heated mirrors. The rear defog
button is an integral part of the manual climate control assembly and a new one cannot be
separately installed.
Function Selector Switch The function selector switch combines a vacuum selector valve that
determines air distribution and an electrical switch to supply battery voltage to the A/C compressor
circuit and the blower motor circuit. When the function selector switch is in the MAX A/C,
DEFROST or FLOOR/DEFROST positions, the A/C compressor will be operational regardless of
the A/C request switch status.
Blower Motor Switch The blower motor switch controls blower motor speed by adding or bypassing
resistors in the blower motor switch resistor in all function selector switch positions except OFF.
Control System Outputs
The climate control system has 5 system outputs.
Blower Motor Resistor The blower motor resistor has 3 resistor elements mounted on the resistor
board to provide 4 blower motor speeds. Depending on the blower motor switch position, series
resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor
speed. The blower motor resistor has an overheating device (thermal limiter) that opens the
resistor coil when the temperature reaches approximately 184°C (363°F), interrupting the blower
motor operation in all speeds except HIGH. The thermal limiter cannot be reset and is not
serviceable.
Temperature Blend Door Actuator The temperature blend door actuator moves the temperature
blend door on command from the temperature control switch using a reversible electric motor. The
temperature blend door actuator contains an internal controller that will recognize the temperature
control switch signal and drive the temperature blend door to the desired position.
The temperature blend door actuator is located on the LH side of the heater core and evaporator
core housing.
Vacuum Control Motors The 4 vacuum control motors move the airflow mode doors to direct
system airflow to the vehicle interior as determined by the function selector switch. Vacuum control
motors are used to control the: air inlet door.
- defrost mode door.
- panel mode door.
- floor mode door.
Heater Control Valve Vacuum Switch
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Control Components > Page 7340
The heater control valve vacuum switch applies vacuum to the heater control valve when the
temperature blend door is in the full COOL position. The temperature blend door actuates the
heater control valve vacuum switch with an arm attached to the RH side of the temperature blend
door pivot shaft.
The heater control valve vacuum switch is mounted on the RH side of the heater core and
evaporator core housing just below the defrost door vacuum control motor.
DUAL-ZONE ELECTRONIC AUTOMATIC TEMPERATURE CONTROL
The dual-zone electronic automatic temperature control (EATC) module analyzes input from the
following major sources:
- Temperature, airflow direction and blower selection (made by the vehicle occupants)
- In-vehicle temperature
- Ambient temperature
- Sunload
- Vehicle speed
- Engine coolant temperature
Using these inputs, the dual-zone EATC module determines the correct conditions for the following
outputs:
- A/C compressor operation
- Blower speed
- LH side temperature blend door position
- RH side temperature blend door position
- Air inlet mode door position
- Defrost mode door position
- Panel mode door position
- Floor mode door position
Control System Inputs
The dual-zone EATC system has 5 control system inputs.
Climate Control Assembly (Dual-Zone EATC Module)
NOTE: If installing a new dual-zone EATC module, the new module must be configured for the
vehicle. Refer to Information Bus (Module Communications Network).
The dual-zone EATC module has a vacuum fluorescent display for displaying set temperature,
airflow direction, blower speed and diagnostic trouble codes (DTCs). The dual-zone EATC module
utilizes an on-board diagnostic (OBD) feature to supply the technician with DTCs. These DTCs
help direct the technician to the inoperative component.
Steering Wheel Audio/Climate Control Switch The steering wheel audio/climate control switch is
located on the right side of the steering wheel. The steering wheel audio/climate control switch
allows the driver to adjust the passenger compartment temperature setting and manually override
the blower motor speed setting.
Ambient Air Temperature Sensor The ambient air temperature sensor contains a thermistor which
measures the temperature of outside air as a resistance and sends that reading to the dual-zone
EATC module.
In-Vehicle Temperature Sensor The in-vehicle temperature sensor contains a thermistor which
measures the in-vehicle air temperature and sends that reading to the EATC module. A hose and
elbow is connected between the heater core and evaporator core housing and the in-vehicle
temperature sensor. The automatic temperature control sensor hose and elbow takes air from the
heater core and evaporator core housing air stream to create a suction in the in-vehicle
temperature sensor. The suction draws in-vehicle air into the in-vehicle temperature sensor and
across the thermistor.
Solar Radiation Sensor (Sunload Sensor) The solar radiation sensor supplies information to the
dual-zone EATC module indicating LH side and RH side sunload.
Control System Outputs
The dual-zone EATC system has 4 control system outputs.
Automatic Temperature Control (ATC) Solenoid and Manifold The ATC solenoid and manifold uses
5 internal solenoid-type valves to distribute vacuum to the vacuum control motors and heater
control valve based on the dual-zone EATC module settings. Manifold vacuum is always available
at the ATC solenoid and manifold from the vacuum reservoir when the engine is running. The 4
vacuum control motors and the heater control valve vacuum lines are each connected to a
separate internal solenoid. The dual-zone EATC module will apply voltage to the desired solenoids
to open the solenoid to the manifold vacuum supply and complete the vacuum circuit to the desired
component.
Blower Motor Speed Control
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Control Components > Page 7341
The blower speed control converts low power signals from the dual-zone EATC module to a high
current, variable ground feed for the blower motor. A delay function is used to provide a gradual
increase or decrease in blower motor speed under all conditions.
Temperature Blend Door Actuators The dual-zone EATC system uses 2 temperature blend door
actuators to control 2 separate temperature blend doors. The temperature blend doors
independently vary the LH side and RH side temperature settings, as desired. The temperature
blend door actuators each contain a reversible electric motor and a potentiometer. The dual-zone
EATC module applies a 5-volt signal to one end of the potentiometer and ground to the other. The
potentiometer wiper is connected to the actuator output shaft and moves with the output shaft. The
voltage available at the wiper indicates the position of the temperature blend door. The actuator
wiper voltage is sent to the dual-zone EATC module which drives the actuator motor in whichever
direction is necessary to make the actuator wiper voltage agree with the expected dual-zone EATC
module wiper voltage value.
Vacuum Control Motors The 4 vacuum control motors move the airflow mode doors to direct
system airflow to the vehicle interior as determined by the function selector switch. Vacuum control
motors are used to control the air inlet door.
- defrost mode door.
- panel mode door.
- floor mode door.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Control Components > Page 7342
Control Assembly: Description and Operation Heating and Ventilation
HEATING AND VENTILATION
The heating and ventilation system has the following features:
- Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside
the vehicle.
- Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
- Cooling or heating can be adjusted to maintain the desired temperature.
- On vehicles with dual-zone electronic automatic temperature control (EATC), the temperature can
be adjusted individually by the driver and passenger.
Heater Core
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
Blower Motor
The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core
housing and the plenum chamber where it is mixed and distributed.
Heater Control Valve
The heater control valve is actuated by the heater control valve vacuum switch (manual climate
control) or the heater control valve vacuum control circuit (EATC). When the heater control valve is
closed (full vacuum), coolant flow through the heater core is shut OFF and A/C cooling efficiency is
increased.
Heater Core and Evaporator Core Housing
The heater core and evaporator core housing directs airflow from the blower motor through the
evaporator core and heater core. All airflow from the blower motor passes through the evaporator
core. The airflow is then directed through or around the heater core by the temperature blend
door(s). Vehicles equipped with dual-zone EATC use a partitioned heater core and evaporator core
housing with 2 electric actuator-positioned temperature blend doors. This allows for separate
temperatures to be selected for the driver and passenger sides of the passenger compartment.
Manual systems use a single electric actuator-positioned temperature blend door to direct airflow
through or around the heater core.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly
Control Assembly: Service and Repair Climate Control Assembly
CLIMATE CONTROL ASSEMBLY
Removal and Installation
NOTE: If installing a new dual-zone electronic automatic temperature control (EATC) module, the
new module must be configured for the vehicle.
All vehicles
1. Remove the center instrument panel finish panel. 2. Remove the 4 climate control assembly
screws. 3. Remove the climate control assembly.
Vehicles with manual climate control
4. Remove the 3 climate control knobs.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly > Page 7345
5. Depress the tabs and remove the blower motor switch.
6. Depress the tabs and remove the function selector switch.
All vehicles
7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Climate Control Assembly > Page 7346
Control Assembly: Service and Repair Auxiliary Climate Control Assembly
AUXILIARY CLIMATE CONTROL ASSEMBLY
Removal and Installation
1. Remove the overhead console. 2. Remove the 2 screws. 3. Remove the bezel. 4. Remove the
auxiliary climate control assembly. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Page 7350
Control Module HVAC: Diagrams
C228A
C228B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair
Coupler HVAC: Service and Repair
SPRING LOCK COUPLING
Special Tool(s)
Special Tool(s)
Disconnect
1. Remove the spring lock coupling clip, if equipped.
2. 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.
Push the tool into the cage opening to release the female fitting from the spring lock coupling
spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool.
3. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring;
this can cause axial scratches across
the O-ring seal grooves resulting in refrigerant leaks.
Remove the spring lock coupling spring with a small hooked wire.
Cleaning
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Page 7354
1. Fabricate a cleaning tool from a 1/8-in diameter brazing rod.
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 oil. 5. Roll the pad on the tool
and install it in a variable speed drill motor.
6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to
prevent axial scratches which may cause
future leaks.
Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free
of scratches or foreign material.
7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves
and scratches are still present, install a new component.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Page 7355
9. Clean the O-ring seal grooves with a 300 mm (12 in) 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
1. Install the spring lock coupling spring.
2. Lubricate the inside of the coupling with PAG oil.
3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those
specified in the Ford Master Parts Catalog may
result in intermittent leakage during vehicle operation.
Install the O-ring seals.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Page 7356
4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling
spring snaps over the flared end of the female
fitting.
5. Install the spring lock coupling clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation
Evaporator Core: Description and Operation
Evaporator Core
NOTE:
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator.
The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator
core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the
evaporator core inlet tube and continues out of the evaporator core through the evaporator core
outlet tube. Air from the blower motor is cooled and dehumidified as it flows through the evaporator
core fins.
Evaporator Core Orifice
NOTE: A new evaporator core orifice should be installed whenever a new A/C compressor is
installed.
The evaporator core orifice is located in the condenser-to-evaporator line, and can be removed
through an access fitting. The evaporator core orifice provides a restriction to the flow of refrigerant
from the high-pressure side of the refrigerant system and separates the low-pressure and
high-pressure sides of the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Operation > Page 7360
Evaporator Core: Service and Repair
EVAPORATOR CORE
Removal and Installation
NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested
before it is removed from the vehicle.
1. Remove the heater core. 2. Remove the 5 outer evaporator core cover screws. 3. Remove the 6
inner evaporator core cover screws. 4. Separate the evaporator core cover from the heater core
and evaporator core housing.
- Discard the rope seal.
5. Remove the evaporator core. 6. To install, reverse the removal procedure.
- Apply a bead of RTV sealant around the entire evaporator core housing groove joint in place of
the rope seal.
- Tighten the evaporator core cover screws in a diagonal pattern to distribute the RTV sealant
evenly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various
A/T Solenoid DTC's
Evaporator Drain Tube: Customer Interest A/T Controls - MIL ON/Various A/T Solenoid DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL ON/Various
A/T Solenoid DTC's > Page 7369
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
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL
ON/Various A/T Solenoid DTC's
Evaporator Drain Tube: All Technical Service Bulletins A/T Controls - MIL ON/Various A/T Solenoid
DTC's
TSB 09-22-15
11/16/09
5R555 TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION
FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR
BEFORE 8/12/2009
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or
before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with
diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related
DTCs. This may be due to water traveling down from the A/C drain into the solenoid body
connector on the left side of the transmission.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Verify any transmission related symptoms or transmission related DTC's that are present.
2. Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be
coming from the A/C drain. (Figure 1)
3. If present, clean the connector thoroughly and apply Motorcraft(R) Electrical Grease as needed.
4. Cut and install patch kit over the connector. (Figure 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 09-22-15 > Nov > 09 > A/T Controls - MIL
ON/Various A/T Solenoid DTC's > Page 7375
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
092215A 2006-2010 Explorer, 0.4 Hr.
Mountaineer 2007-2010 Explorer Sport Trac 4.0L: Check DTCs, Inspect, Clean, And Grease
Connector, Install Patch (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7G391 X2
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance
The ACET sensor measures the 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 the resistance 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 changes 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, improve defrost/demist
performance, and reduce A/C clutch cycling.
NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were
calculated for VREF equals 5.0 volts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair
Expansion Block/Orifice Tube: Service and Repair
EVAPORATOR CORE ORIFICE
Special Tool(s)
Special Tool(s)
Removal
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
1. Recover the refrigerant.
2. NOTE: The evaporator core orifice access fitting is located in the condenser-to-evaporator line
below the powertrain control module.
Disconnect the evaporator core orifice access fitting. Discard the O-ring seal.
3. Inspect the evaporator core orifice for damage before attempting to remove it from the line.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair > Page 7382
4. If the evaporator core orifice is intact, engage the special tool. Hold the T-handle stationary while
rotating the tool body to remove the evaporator
core orifice.
5. If the evaporator core orifice is broken, screw the end of the special tool into the broken orifice.
Hold the T-handle stationary while rotating the
tool body to remove the evaporator core orifice.
Installation
1. Lubricate the evaporator core orifice O-rings with clean PAG oil and install the evaporator core
orifice using the special tool. 2. Install a new O-ring seal and connect the evaporator core orifice
access fitting.
- To install, tighten to 24 Nm (18 lb-ft).
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. 4. Evacuate, leak test
and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair
Expansion Valve: Service and Repair
THERMOSTATIC EXPANSION VALVE
Removal and Installation
NOTE:
- An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan bracket connection.
A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve. This filter
must be inspected before a new thermostatic expansion valve is installed.
- Installation of a new suction accumulator is not required when repairing the air conditioning
system, except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
1. Recover the refrigerant. 2. Remove the D-pillar trim panel. 3. Detach the rear portion of the LH
quarter trim panel and position away from the thermostatic expansion valve. 4. Remove the 4 clips
and the thermostatic expansion valve cover.
5. Remove the insulating tape.
- Retain the tape for reuse.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair
> Page 7386
6. Remove the temperature sensing bulb clip and detach the temperature sensing bulb from the
evaporator outlet line. 7. Disconnect the 2 thermostatic expansion valve fittings and remove the
thermostatic expansion valve.
- Discard the O-ring seals.
- To install, tighten to 23 Nm (17 lb-ft).
8. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
9. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Service and
Repair
Heater Control Valve: Service and Repair
HEATER CONTROL VALVE
Removal and Installation
Vehicles with 4.0L and oil cooler, without auxiliary climate control
1. With the vehicle in NEUTRAL, position it on a hoist.
All vehicles
2. Drain the engine coolant. 3. Disconnect the 2 inlet and outlet heater hose clamps. 4. Disconnect
the heater control valve vacuum hose.
Vehicles with 4.0L and oil cooler, without auxiliary climate control
5. Remove the heater control valve bolt.
All vehicles
6. Remove the heater control valve.
7. NOTE: Lubricate the coolant hoses with plain water only if needed.
To install, reverse the removal procedure.
8. Fill the engine cooling system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7398
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7399
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7405
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7406
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core
Heater Core: Service and Repair Heater Core
HEATER CORE
Removal and Installation
NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is
removed from the vehicle.
1. Remove the heater core and evaporator core housing. 2. Remove the 2 LH floor duct screws. 3.
Remove the LH floor duct. 4. Remove the 2 RH floor duct screws. 5. Remove the RH floor duct. 6.
Remove the 3 housing brace screws. 7. Remove the housing brace.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7409
8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover.
10. Remove the heater tube seal. 11. Remove the 4 heater core cover screws. 12. Remove the
heater core cover. 13. Remove the heater core. 14. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7410
Heater Core: Service and Repair Auxiliary Heater Core
AUXILIARY HEATER CORE
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7411
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant.
3. Release the 2 heater hose clamps and disconnect the heater hoses.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Heater Core > Page 7412
4. Remove the rear quarter trim panel.
5. Remove the 2 auxiliary line floorpan bracket nuts.
6. NOTE: The screw and line bracket are located inside the vehicle above the floorpan line bracket.
Remove the 4 line bracket screws and the line bracket.
7. Disconnect the auxiliary harness electrical connector. 8. Remove the 2 auxiliary housing bolts
and auxiliary housing nut.
- To install, tighten to 6 Nm (53 lb-in).
9. Disconnect the 2 auxiliary actuator electrical connectors.
10. Remove the 3 auxiliary mode door actuator screws. 11. Remove the auxiliary mode door
actuator. 12. Remove the 3 auxiliary temperature blend door actuator screws. 13. Remove the
auxiliary temperature blend door actuator. 14. Remove the 4 heater core cover screws. 15.
Remove the heater core cover. 16. Disconnect the 2 heater core hose clamps. 17. Remove the
auxiliary heater core. 18. To install, reverse the removal procedure.
- Lubricate the coolant hoses with plain water only if needed.
19. Fill the engine cooling system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7421
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7422
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7428
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7429
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Heater Outlet and Inlet Line - Front
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Front
AUXILIARY HEATER OUTLET AND INLET LINE - FRONT
Removal and Installation
1. Remove the RH running board. 2. Drain the engine coolant. 3. Remove the RH rear wheel. 4.
Release the front auxiliary heater line front clamps and disconnect the heater hoses. 5. Release
the front auxiliary heater line rear clamps and disconnect the heater hoses. 6. Remove the 3
auxiliary line bracket nuts.
- To install, tighten to 6 Nm (53 lb-in).
7. Remove the 3 auxiliary line bracket bolts.
- To install, tighten to 6 Nm (53 lb-in).
8. Remove the 6 auxiliary line brackets. 9. Remove the front auxiliary heater outlet and inlet lines.
10. To install, reverse the removal procedure. 11. Fill the engine cooling system,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Heater Outlet and Inlet Line - Front > Page 7432
Heater Hose: Service and Repair Auxiliary Heater Outlet and Inlet Line - Rear
AUXILIARY HEATER OUTLET AND INLET LINE - REAR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. Remove the
spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type
retainers. 5. Remove the spare tire carrier. 6. Release the 2 rear auxiliary heater line front hose
clamps and disconnect the hoses. 7. Release the 2 rear auxiliary heater line rear hose clamps and
disconnect the hoses. 8. Remove the 2 auxiliary line bracket nuts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Auxiliary Heater Outlet and Inlet Line - Front > Page 7433
- To install, tighten to 8 Nm (71 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary heater outlet line. 11. Remove the rear auxiliary heater inlet line. 12.
To install, reverse the removal procedure. 13. Fill the engine cooling system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation
High Pressure Safety Valve HVAC: Description and Operation
A/C COMPRESSOR PRESSURE RELIEF VALVE
An A/C compressor pressure relief valve is installed in the compressor to relieve unusually high
refrigerant system discharge pressure buildups. The compressor pressure relief valve will avoid
total refrigerant loss by closing after the excessive pressure has been relieved.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When Compressor Cycles
Hose/Line HVAC: Customer Interest A/C - Thump Noise When Compressor Cycles
TSB 06-12-12
06/26/06
A/C COMPRESSOR THUMP NOISE WITH 4.0L V-6
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Explorer Sport Trac vehicles built with a
4.0L V-6 engine and built before 2/7/2006, may exhibit an intermittent thump or similarly described
noise transmitted into the passenger compartment in A/C / Auto / Defrost modes, when the A/C
compressor engages. The noise may occur when the A/C suction line makes contact with the sheet
metal cowl in the engine compartment. The identified thump or similar noise may be audible behind
the instrument cluster when driving and may also only occur intermittently under hard
accelerations.
ACTION Use the following Service Procedure to insulate the A/C suction line from contact with the
cowl. Apply an adhesive foam block between the A/C suction line and cowl sheet metal in the area
of potential contact.
NOTE
A/C COMPRESSORS SHOULD NOT BE REPLACED TO CORRECT THIS CONDITION.
SERVICE PROCEDURE
1. Visually inspect for the presence of a foam block between the suction line and cowl shown in
Figure 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When Compressor Cycles
> Page 7445
2. If the foam block is already present, ensure that it is properly positioned to insulate the line from
the cowl (Figure 2). If the foam block is present and positioned properly do not continue with this
TSB.
3. If the foam block is missing, install one (1). The adhesive side should face the sheet metal of the
cowl and should be installed in line with the center of the A/C line ferrel (Figure 2).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061212A 2006 Explorer/Mountaineer, 0.2 Hr.
2007 Explorer Sport Trac 4.0L: Install Or Position Foam Block
DEALER CODING
CONDITION
BASIC PART NO. CODE
19N617 43
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When
Compressor Cycles
Hose/Line HVAC: All Technical Service Bulletins A/C - Thump Noise When Compressor Cycles
TSB 06-12-12
06/26/06
A/C COMPRESSOR THUMP NOISE WITH 4.0L V-6
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Explorer Sport Trac vehicles built with a
4.0L V-6 engine and built before 2/7/2006, may exhibit an intermittent thump or similarly described
noise transmitted into the passenger compartment in A/C / Auto / Defrost modes, when the A/C
compressor engages. The noise may occur when the A/C suction line makes contact with the sheet
metal cowl in the engine compartment. The identified thump or similar noise may be audible behind
the instrument cluster when driving and may also only occur intermittently under hard
accelerations.
ACTION Use the following Service Procedure to insulate the A/C suction line from contact with the
cowl. Apply an adhesive foam block between the A/C suction line and cowl sheet metal in the area
of potential contact.
NOTE
A/C COMPRESSORS SHOULD NOT BE REPLACED TO CORRECT THIS CONDITION.
SERVICE PROCEDURE
1. Visually inspect for the presence of a foam block between the suction line and cowl shown in
Figure 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 06-12-12 > Jun > 06 > A/C - Thump Noise When
Compressor Cycles > Page 7451
2. If the foam block is already present, ensure that it is properly positioned to insulate the line from
the cowl (Figure 2). If the foam block is present and positioned properly do not continue with this
TSB.
3. If the foam block is missing, install one (1). The adhesive side should face the sheet metal of the
cowl and should be installed in line with the center of the A/C line ferrel (Figure 2).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061212A 2006 Explorer/Mountaineer, 0.2 Hr.
2007 Explorer Sport Trac 4.0L: Install Or Position Foam Block
DEALER CODING
CONDITION
BASIC PART NO. CODE
19N617 43
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line
Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line
COMPRESSOR TO CONDENSER DISCHARGE LINE
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the air
cleaner and air cleaner outlet tube. 4. Remove the compressor-to-condenser discharge line bracket
nut and detach the bracket.
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the compressor outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.
- To install, tighten to 15 Nm (11 lb-ft).
6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside.
- To install, tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7454
7. Disconnect the A/C pressure transducer electrical connector. 8. Remove the condenser inlet
fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
9. NOTE: The LH clip should be disconnected from the line. The RH clip should be disconnected
from the cooling module.
Detach the 2 compressor-to-condenser discharge line clips at the cooling module.
10. Remove the compressor-to-condenser discharge line. 11. To install, reverse the removal
procedure.
- Install a new gasket seal and O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7455
Hose/Line HVAC: Service and Repair Condenser to Evaporator Line
CONDENSER TO EVAPORATOR LINE
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
All vehicles
1. Remove the air cleaner and air cleaner outlet tube. 2. Recover the refrigerant. 3. Remove the
powertrain control module (PCM) and PCM bracket. 4. Disconnect the RH wheel speed sensor
electrical connector and detach the wire harness from the condenser-to-evaporator line bracket.
Vehicles equipped with 4.6L engine
5. Remove the suction accumulator-to-compressor line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
All vehicles
6. Disconnect the evaporator core orifice access fitting.
- Discard the O-ring seal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7456
7. Remove the condenser-to-evaporator line bracket nut.
- To install, tighten to 7 Nm (62 lb-in).
8. Remove the condenser outlet fitting nut and disconnect the fitting.
- Discard the O-ring seal.
- To install, tighten to 8 Nm (71 lb-in).
9. Disconnect the auxiliary evaporator inlet line fitting (if equipped).
- Discard the O-ring seals.
10. Remove the front portion of the condenser-to-evaporator line. 11. Remove the A/C line bracket
nut at the dash panel and detach the bracket.
- To install, tighten to 6 Nm (53 lb-in).
12. Disconnect the evaporator inlet fitting.
- Discard the O-ring seals.
13. Remove the rear portion of the condenser-to-evaporator line. 14. To install, reverse the removal
procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
15. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7457
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - FRONT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7458
Part 2
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system, except when there is physical evidence of contamination from a failed A/C compressor or
damage to the accumulator.
1. Recover the refrigerant. 2. Disconnect the front auxiliary evaporator inlet line front fitting.
- Discard the O-ring seals.
3. Remove the RH running board. 4. Disconnect the front auxiliary evaporator outlet line front
fitting. 5. Remove the RH rear wheel. 6. Remove the front auxiliary evaporator line fitting nuts and
disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 3 auxiliary line bracket nuts.
- To install, tighten to 6 Nm (53 lb-in).
8. Remove the 3 auxiliary line bracket bolts.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 6 auxiliary line brackets.
10. Remove the front auxiliary evaporator outlet and inlet lines. 11. To install, reverse the removal
procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
12. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7459
Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear
AUXILIARY EVAPORATOR OUTLET AND INLET LINE - REAR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor to Condenser Discharge Line > Page 7460
Part 2
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the accumulator.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the
spare tire. 4. Remove the 4 spare tire carrier bolts and the 2 spare tire carrier shield pin-type
retainers. 5. Remove the spare tire carrier. 6. Remove the 2 rear auxiliary evaporator line front
fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
7. Remove the 2 rear auxiliary evaporator line rear fitting nuts and disconnect the fittings.
- Discard the O-ring seals.
- To install, tighten to 8 Nm (71 lb-in).
8. Remove the auxiliary line bracket nut.
- To install, tighten to 6 Nm (53 lb-in).
9. Remove the 2 auxiliary line brackets.
10. Remove the rear auxiliary evaporator outlet line. 11. Remove the rear auxiliary evaporator inlet
line.
- Discard the thermostatic expansion valve (TXV) filter.
12. To install, reverse the removal procedure.
- Install new O-ring seals.
- Install a new TXV filter.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
13. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing
Housing Assembly HVAC: Service and Repair Heater Core and Evaporator Core Housing
HEATER CORE AND EVAPORATOR CORE HOUSING
Removal and Installation
NOTE:
- If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it
is removed from the vehicle.
- Installation of a new suction accumulator is not required when repairing the air conditioning
system, except when there is physical evidence of contamination from a failed A/C compressor or
damage to the accumulator.
- Lubricate the coolant hoses with plain water only if needed.
1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7465
4. Detach the wiring harness bracket and position the harness aside.
5. Remove the heater tube bracket nut.
6. Remove the A/C line bracket nut at the dash panel.
- To install, tighten to 11 Nm (8 lb-ft).
7. Disconnect the 2 heater hose clamps at the heater core. 8. Disconnect the evaporator inlet
fitting.
- Discard the O-ring seals.
9. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7466
10. Disconnect the 2 vacuum connectors.
11. Detach the grommet and push the vacuum lines into the passenger compartment. 12. Remove
the 4 heater core and evaporator core housing nuts.
- To install, tighten to 9 Nm (80 lb-in).
13. Disconnect the ground terminal bolt. 14. Remove the heater core and evaporator core housing.
15. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
16. Fill and the engine cooling system. 17. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7467
Housing Assembly HVAC: Service and Repair Plenum Chamber
PLENUM CHAMBER
Removal and Installation
1. Remove the instrument panel. 2. Remove the audio unit. 3. Remove the 3 plenum chamber
screws. 4. Remove the instrument panel upper finish panel. 5. Remove the 3 defroster duct
screws. 6. Remove the defroster duct. 7. Remove the plenum chamber. 8. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7468
Housing Assembly HVAC: Service and Repair Auxiliary Heater Core and Evaporator Core Housing
AUXILIARY HEATER CORE AND EVAPORATOR CORE HOUSING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7469
Removal and Installation
NOTE:
- Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the accumulator.
- Clean and lubricate the coolant hoses with plain water only if needed.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Drain the
engine coolant. 4. Remove the LH quarter trim panel. 5. Detach the headliner duct from the
auxiliary climate control housing. 6. Remove the auxiliary evaporator inlet and outlet line fitting
nuts.
- Discard the O-ring seals.
- Discard the thermostatic expansion valve (TXV) filter.
- To install, tighten to 8 Nm (71 lb-in).
7. Release the heater hose clamps and disconnect the heater hoses.
- After disconnecting the heater hoses, allow any residual coolant to drain from the auxiliary heater
core to avoid coolant spilling inside the passenger compartment.
8. Remove the 2 auxiliary line floorpan bracket nuts.
- To install, tighten to 8 Nm (71 lb-in).
9. Remove the 2 auxiliary heater core and evaporator core housing bolts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Heater Core and Evaporator Core Housing > Page 7470
- To install, tighten to 6 Nm (53 lb-in).
10. Remove the auxiliary heater core and evaporator core housing nut.
- To install, tighten to 6 Nm (53 lb-in).
11. Disconnect the auxiliary harness electrical connector. 12. Remove the auxiliary heater core and
evaporator core housing. 13. To install, reverse the removal procedure.
- Clean and lubricate the coolant hoses with plain water only if needed.
- Install new O-ring seals.
- Install a new TXV filter.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.
14. Fill the engine cooling system. 15. Evacuate, leak test and charge the refrigerant system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Capacity
Capacity without auxiliary climate control.............................................................................................
......................................................0.88 kg (31 oz) Capacity with auxiliary climate control...................
.....................................................................................................................................1.33 kg (47 oz)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 7475
Refrigerant: Fluid Type Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Type
R134a Refrigerant YN-19 ....................................................................................................................
.................................................. WSH-M17B19-A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
7476
Refrigerant: Description and Operation
REFRIGERANT SYSTEM DYE
Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in
refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not
necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a
significant amount of refrigerant has been removed from the system. Replacement suction
accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will
dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye
after flushing or filtering the refrigerant system because a new suction accumulator is installed as
part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if
more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation,
hose rupture or other damage.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Oil Capacity
Capacity without auxiliary climate control.............................................................................................
......................................................266 ml (9 fl oz) Capacity with auxiliary climate control...................
...................................................................................................................................473 ml (16 fl oz)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 7481
Refrigerant Oil: Fluid Type Specifications
Item.......................................................................................................................................................
..............................................................Specification
Refrigerant Oil Type
PAG Refrigerant Compressor Oil (R-134a Systems) YN-12-D
............................................................................................................. WSH-M1C231-B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure
Sensor / Switch, HVAC > Component Information > Locations > Page 7486
C1078
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay 1 > Page 7492
View 151-10 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 7493
C2017
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Testing and Inspection > Blower Motor Relay 1 > Page 7496
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7500
Compressor Clutch Relay: Description and Operation
AIR CONDITIONING (A/C) CLUTCH RELAY (A/CCR)
NOTE: The PCM PIDs WAC and wide open throttle air conditioning cutoff fault (WACF) are used to
monitor the A/CCR output.
The A/CCR is wired normally open. There is no direct electrical connection between the A/C switch
or electronic automatic temperature control (EATC) module and the A/C clutch. The PCM receives
a signal indicating that A/C is requested. For some applications, this message is sent through the
communications network. When A/C is requested, the PCM checks other A/C related inputs that
are available, such as A/C pressure switch and A/C cycling switch. If these inputs indicate A/C
operation is OK, and the engine conditions are OK (coolant temperature, engine RPM, throttle
position), the PCM grounds the A/CCR output, closing the relay contacts and sending voltage to
the A/CCR.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 7501
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Page 7505
Control Module HVAC: Diagrams
C228A
C228B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Locations
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Locations > Page 7510
C2208
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7514
C132
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 7515
Ambient Temperature Sensor / Switch HVAC: Service and Repair
AMBIENT AIR TEMPERATURE SENSOR
Removal and Installation
Mountaineer
1. Remove the radiator grille.
2. Remove the pin-type retainers and position the air deflector forward. 3. Remove the 2 air
deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator
support.
All vehicles
4. Detach the ambient air temperature sensor electrical connector. 5. Remove the ambient air
temperature sensor. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations
View 151-11 (Front HVAC)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 7519
C271
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Page 7520
Blower Motor Switch: Service and Repair
BLOWER MOTOR SPEED CONTROL
Removal and Installation
1. Remove the blower motor speed control screw. 2. Remove the blower motor speed control. 3.
Disconnect the blower motor speed control electrical connector. 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7524
C233
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 7525
Cabin Temperature Sensor / Switch: Service and Repair
IN-VEHICLE TEMPERATURE SENSOR
Removal and Installation
1. Remove the instrument cluster finish panel. 2. Remove the in-vehicle temperature sensor. 3. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Description and Operation
Evaporator Temperature Sensor / Switch: Description and Operation
AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) SENSOR
A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance
The ACET sensor measures the 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 the resistance 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 changes 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, improve defrost/demist
performance, and reduce A/C clutch cycling.
NOTE: These values can vary 15% due to sensor and VREF variations. Voltage values were
calculated for VREF equals 5.0 volts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7533
C1078
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 7537
C286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and
Operation
Service Port HVAC: Description and Operation
SERVICE GAUGE PORT VALVES
The high-pressure service gauge port valve is located on the compressor-to-condenser discharge
line.
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 very small amount of leakage will always be detectable around the Schrader-type valve with the
service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core
can be installed if the seal leaks excessively.
- The service gauge port valve caps are used as primary seals in the refrigerant system to prevent
leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten
the A/C service gauge port valve caps to the correct torque after they are removed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 7544
C286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and
Repair
Vacuum Harness HVAC: Service and Repair
VACUUM HOSE REPAIR - MINI-TUBE
Special Tool(s)
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 in) longer than the
damaged area of the mini-tube vacuum
hose.
3. Cut off the mini-tube vacuum hose on each side of the damaged area.
4. WARNING: Read the warning information on the product label to prevent possible personal
injury.
Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone
(MEK). This solvent will seal the mini-tube in the vacuum hose.
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 in) into the ends of the
standard 1/8-inch repair vacuum hose. 6. Shake the repair joint after assembly to make sure the
solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in
the repair area.
- Use the vacuum pump or equivalent.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service
and Repair
Vacuum Reservoir HVAC: Service and Repair
VACUUM RESERVOIR
Removal and Installation
1. Remove the vacuum reservoir screw. 2. Remove the vacuum reservoir. 3. Disconnect the
vacuum connector. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations > Page 7554
C2093
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment
Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After
A Supplemental Restraint System (SRS) Deployment
INSPECTION AND REPAIR AFTER A SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
DEPLOYMENT
WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from
vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle
safety standards.
NOTE:
- After diagnosing or repairing a supplemental restraint system (SRS), the restraint system
diagnostic tools (if required) must be removed before operating the vehicle over the road.
- After diagnosing or repairing a seat system, the restraint system diagnostic tools (if required) must
be removed before operating the vehicle over the road.
- Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various
combinations depending on the impact event.
- Always refer to the appropriate procedures prior to carrying out vehicle repairs affecting the
supplemental restraint system (SRS) and safety belt system.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices are deployed and/or the restraints control
module (RCM) has the diagnostic trouble code (DTC) B1231 (Crash Data Memory Full) in memory,
the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation
of new deployable devices, the removal and installation of new impact sensors, and the removal
and installation of a new RCM. DTCs must cleared from all required modules after repairs are
carried out.
Vehicles with occupant classification sensor (OCS) system
2. NOTE: After installation of new occupant classification sensor (OCS) components carry out the
OCS System Reset procedure as instructed.
Refer to the appropriate OCS system removal and installation procedure.
When a vehicle has been involved in a collision and the occupant classification sensor (OCS)
module has DTC B1231 stored in memory, the repair of the OCS system is to include the following
procedures for the specified system: For rail type OCS system, inspect the passenger side floorpan for damage and repair as
necessary. Install new OCS rails.
- For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and
repair as necessary. Install a new seat track with OCS weight sensor bolts.
- NOTE: Most bladder type OCS modules do not store a DTC B1231 in memory after deployment.
The DTC B1231 is stored only by the RCM.
For bladder type OCS system, inspect for damage and repair as necessary. If installation of an
OCS component is required, an OCS service kit must be installed.
All vehicles
3. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting
hardware as needed.
4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New
driver and/or front passenger safety belt systems (including retractors, buckles and height
adjusters) must be installed if the vehicle is
involved in a collision that results in deployment of the driver and/or front passenger safety belt
pretensioners.
6. Inspect the entire vehicle for damage, including the following components:
- Steering column (deployable column if equipped)
- Instrument panel knee bolsters and mounting points
- Instrument panel braces and brackets
- Instrument panel and mounting points
- Seats and seat mounting points
- Safety belts, safety belt buckles and safety belt retractors.
- SRS wiring, wiring harnesses and connectors
7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7560
Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After
A Collision
SAFETY BELT PROCEDURE AFTER A COLLISION
WARNING: All safety belt assemblies (including retractors, belt tension sensor [BTS], if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after every collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of personal injury in collisions.
1. Before installing a 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 worked back to its original shape and structural
integrity.
2. Install the new safety belt(s). Carry out the Functional Test. See: Seat Belt Systems/Testing and
Inspection/Component Tests and General
Diagnostics
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Special Tool(s)
Special Tool(s)
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box
(SJB), located below the LH side of the instrument panel, remove the cover and the restraints
control module (RCM)
fuse 17 (10A) from the SJB.
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 switch to OFF.
6. WARNING: To avoid accidental deployment and possible personal 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
servicing, 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.
The front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7566
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.
2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the
cover.
4. 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.
5. Prove out the SRS as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7567
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment, which can result in personal injury.
- The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always
wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never
probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in
pretensioner, adaptive load limiting retractor or air bag deployment and could 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 reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7568
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart
junction box (SJB), located below the LH side of the instrument panel, remove the cover and the
restraints control module (RCM)
fuse 17 (10A) from the SJB.
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 front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
7. Remove the 2 driver air bag module bolts (1 shown).
8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation.
Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7569
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
10. Open and lower the glove compartment door.
11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield.
12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive
tether squibs do not require deactivation.
Through the glove compartment opening, disconnect the LH side passenger air bag module
electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector on the LH side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7570
14. From under the rear of the passenger seat, detach the passenger seat side air bag module
electrical connector from the seat track bracket. Then
slide and disengage the passenger seat side air bag module electrical connector locking clip, and
then release the tab and disconnect the passenger seat side air bag module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Vehicles without safety canopy modules
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM.
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Explorer and Mountaineer vehicles with safety canopy modules
17. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7571
18. Disconnect the passenger side safety canopy module electrical connector.
19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
20. Release and position aside the driver side C-pillar trim panel.
21. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7572
22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles with safety canopy modules
23. Remove the driver and passenger side upper C-pillar trim panels.
24. Disconnect the passenger side safety canopy module electrical connector.
25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
26. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7573
27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles
28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module
electrical connector locking clip, and then release
the tab and disconnect the driver seat side air bag module electrical connector.
29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the
battery ground cable.
Reactivation
All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7574
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side
air bag module electrical connector.
4. Connect the driver seat side air bag module electrical connector and then slide and engage the
seat side air bag electrical connector locking clip.
Explorer Sport Trac vehicles with safety canopy modules
5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
6. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7575
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy module electrical connector.
8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and
passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles with safety canopy modules
10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
11. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7576
12. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
side safety canopy module electrical connector.
14. Connect the passenger side safety canopy module electrical connector.
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7577
16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
seat side air bag module electrical connector.
17. Connect the passenger seat side air bag module electrical connector and then slide and
engage the seat side air bag electrical connector locking
clip. Then attach the passenger seat side air bag module electrical connector to the seat track
bracket.
18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector on the LH side.
19. Connect the LH side passenger air bag module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7578
20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21.
Close glove compartment door.
22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the
driver air bag module in the wrong
position. Match the electrical connector key to the keyway in the driver air bag module. Do not force
the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted in removal.
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7579
25. 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.
26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and
install the cover.
28. 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.
29. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch back to ON and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a
scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left > Page 7584
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air
Bag Module, Left > Page 7585
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1
C216A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7588
C216B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7589
C216C
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7590
C2351
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7591
Air Bag: Diagrams
C216A
C216B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7592
C216C
C2351
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7593
C367
C337
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7594
C256
C9006
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver
Air Bag Unit 1 > Page 7595
C9007
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and
Operation > Driver and Passenger Air Bag Module
Air Bag: Description and Operation Driver and Passenger Air Bag Module
Driver Air Bag Module
The driver air bag module: contains dual stage deployment (advanced restraint system).
- is equipped with canister vent.
- is installed new as an assembly.
- is mounted in the center of the steering wheel.
In addition to dual stage deployment (advanced restraint system) driver air bag module, this vehicle
is equipped with a driver air bag canister vent. Canister venting is a deployable device integrated to
the driver air bag module. Canister venting controls the inflation rate of the driver air bag, and the
escape rate of gases from the vent.
Passenger Air Bag Module
The passenger air bag module: contains dual stage deployment (advanced restraint system).
- is equipped with canister vent.
- is equipped with adaptive tether.
- is installed new as an assembly.
- is mounted in the passenger side of the instrument panel.
Passenger Air Bag Module
In addition to dual stage deployment (advanced restraint system) front passenger air bag module,
this vehicle is equipped with a passenger air bag adaptive tether as well as a passenger air bag
canister vent. Canister venting is a deployable device integrated to the passenger air bag module.
Canister venting controls the inflation rate of the passenger air bag, and the escape rate of gases
from the vent. Adaptive tether is a deployable device integrated to the passenger air bag module.
Adaptive tether restricts the rearward movement of the passenger air bag.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and
Operation > Driver and Passenger Air Bag Module > Page 7598
Air Bag: Description and Operation Safety Canopy Module
SAFETY CANOPY MODULE
WARNING: Anytime the safety canopy has deployed, the headliner, and all A-, B-, C- and D-pillar
(Explorer/Mountaineer) upper trim panels and attaching hardware must be replaced along with any
other damaged components and hardware. Failure to do so can result in personal injury in the
event of a safety canopy deployment.
The safety canopy module:
- is installed as an assembly.
- is mounted above the headliner.
- attaches from the A-pillar frame to the D-pillar frame on Explorer/Mountaineer and from the
A-pillar frame to the C-pillar frame on Explorer Sport Trac.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module
Air Bag: Service and Repair Driver Air Bag Module
DRIVER AIR BAG MODULE
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.
- 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.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7601
1. Depower the system. 2. Remove the 2 driver air bag module bolts.
- To install, tighten to 7 Nm (62 lb-in).
3. CAUTION: The clockspring electrical connectors are unique and cannot be installed in the wrong
position on the driver air bag module.
Match the electrical connector key to the keyway in the driver air bag module. Do not force the
electrical connectors into the driver air bag module.
NOTE: Note the position of the locator holes in the back of the driver air bag module and locator
tabs on the steering wheel for installation.
Disconnect the 3 electrical connectors and remove the drivers air bag module.
4. To install, reverse the removal procedure. 5. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7602
Air Bag: Service and Repair Passenger Air Bag Module
PASSENGER AIR BAG MODULE
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and deployment door pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the deployment door face down. This will reduce the
risk of injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7603
irritating to the skin. Wash your hands with soap and water afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Air bag modules with discolored or damaged deployment doors must be replaced, not repainted.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Open and lower the glove compartment door.
3. Release the wiring retainer, then remove the 4 bolts and the passenger air bag module heat
shield.
4. Through the glove compartment opening, disconnect the 2 passenger air bag module electrical
connectors. 5. Through the glove compartment opening, remove the 4 air bag module nuts.
- To install, tighten to 9 Nm (80 lb-in).
6. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Through the glove compartment opening, push up to release the deployment door clips from the
instrument panel (I/P) and push the passenger air bag module out of the I/P and remove.
7. NOTE: During air bag module installation, make sure all the deployment door clips are fully
seated into the I/P.
To install, reverse the removal procedure.
8. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7604
Air Bag: Service and Repair Safety Canopy Module
SAFETY CANOPY MODULE
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7605
Part 2
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury from an accidental deployment, always carry or place a live
safety canopy module with the safety canopy and tear seam pointed away from your body. Failure
to do so can result in personal injury in the event of a safety canopy module deployment.
- Anytime the safety canopy has deployed, the headliner, and all A-, B- and C-pillar, upper trim
panels and attaching hardware must be installed new along with any other damaged components
and hardware. Failure to do so can result in personal injury in the event of a safety canopy
deployment.
- Vehicles equipped with safety canopy modules require a specific headliner. When installing a new
headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety
canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets
each B-pillar trim panel. Failure to do so can result in personal injury in the event of a safety
canopy module deployment.
- Before installing a safety canopy module, inspect the roof line for any damage. If necessary, the
sheet metal must be reworked to its original condition and structural integrity. All damaged
fasteners must be installed new and any foreign material removed. Failure to do so may result in
personal injury in the event of a safety canopy deployment.
- Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has
separated and the canopy material has been exposed, a new safety canopy module must be
installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can
result in personal injury in the event of a safety canopy module deployment.
- To reduce the risk of injury, do not obstruct or place objects in the deployment path of the safety
canopy module. Failure to follow these instructions can result in personal injury in the event of a
safety canopy module deployment.
- Never put any type of fastener or tie strap around any part of the safety canopy module or interior
trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so
can result in personal injury in the event of a safety canopy module deployment.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
- The safety canopy must be installed in the vehicle using new torque-prevailing type J-nuts
(W520822, 8 per side). Use of this J-nut is mandatory so as to reduce the risk of loss of fastener
effectiveness. Failure to follow these instructions may result in personal injury in the event of a
safety canopy deployment.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- RH side safety canopy module shown, LH side similar.
All vehicles 1. Depower the system. 2. Remove the headliner.
Vehicles with moonroof
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7606
3. NOTE: Note the position of the 2 rear moonroof drain hose routing clips for installation.
Disconnect the rear moonroof drain tube and detach the 2 rear moonroof drain hose routing clips.
All vehicles 4. Disconnect the safety canopy module electrical connector and detach the connector
pin-type retainer from the C-pillar.
5. NOTE: Note the locator tab on the front tether anchor bracket to the A-pillar sheet metal for
installation.
Remove the bolt and the front tether anchor bracket.
6. Detach the 3 safety canopy module front tether pin-type retainers from the A-pillar. 7. Remove
the 3 front bolts from the safety canopy module. 8. Remove the 2 rear bracket bolts from the safety
canopy module. 9. Remove the 2 bolts and the safety canopy module C-pillar tether bracket.
10. Remove the 2 safety canopy module bolts near the C-pillar.
11. Gently lift the safety canopy module up and inward at the B-pillar to release the bracket hook
from the sheet metal.
12. Move the safety canopy module forward to release the rear bracket hook from the sheet metal
and remove the safety canopy module.
Installation
WARNING:
- Before installing a safety canopy module, inspect the roof line for any damage. If necessary, the
sheet metal must be reworked to its original condition and structural integrity. All damaged
fasteners must be installed new and any foreign material removed. Failure to do so may result in
personal injury in the event of a safety canopy deployment.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7607
- Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has
separated and the canopy material has been exposed, a new safety canopy module must be
installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can
result in personal injury in the event of a safety canopy module deployment.
- Never put any type of fastener or tie strap around any part of the safety canopy module or interior
trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so
can result in personal injury in the event of a safety canopy module deployment.
- The safety canopy must be installed in the vehicle using new torque-prevailing type J-nuts
(W520822, 8 per side). Use of this J-nut is mandatory so as to reduce the risk of loss of fastener
effectiveness. Failure to follow these instructions may result in personal injury in the event of a
safety canopy deployment.
All vehicles
1. Remove the front 4 J-nuts and install new.
2. Remove the rear 4 J-nuts and install new.
3. Position the safety canopy module by moving it rearward, installing the rear bracket hook in the
sheet metal.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module > Page 7608
4. Install the safety canopy module B-pillar bracket hook in the sheet metal.
5. NOTE: Make sure all safety canopy module bolt holes line up with all J-clips.
Install the 2 safety canopy module bolts near the C-pillar. Tighten to 8 Nm (71 lb-in).
6. Install the safety canopy module C-pillar tether bracket and the 2 bolts.
- Tighten to 12 Nm (9 lb-ft).
7. Install the 2 safety canopy module rear bracket bolts.
- Tighten to 8 Nm (71 lb-in).
8. Install the safety canopy module front 3 bolts.
- Tighten to 8 Nm (71 lb-in).
9. Attach the 3 safety canopy module front tether pin-type retainers to the A-pillar.
10. NOTE: Make sure the safety canopy module front tether bracket locator tab is correctly
installed in the A-pillar sheet metal.
Install the safety canopy module front tether bracket and bolt. Tighten to 8 Nm (71 lb-in).
11. Connect the safety canopy module electrical connector and attach the connector pin-type
retainer to the C-pillar.
Vehicles with moonroof
12. NOTE: Make sure to route the moonroof drain hose as noted during removal.
Connect the rear moonroof drain tube and attach the 2 rear moonroof drain hose clips.
All vehicles 13. Install the headliner. 14. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7613
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7614
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7615
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7616
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7617
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7618
^ 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 7619
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7620
Air Bag Control Module: Locations
View 151-15 (Center Console)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7621
View 151-17 (Right Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7622
Air Bag Control Module: Diagrams
C310A
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7623
C310B (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7624
C310B (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7625
Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed.
In addition, make sure the area of the RCM mounting is restored to its original condition.
CAUTION: When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry
out programmable module installation (PMI).
NOTE: When installing a new RCM, always make sure the correct RCM is being installed. If an
incorrect RCM is installed, erroneous DTCs will result.
The RCM carries out the following functions:
- deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioner and safety belt adaptive load limiting retractor to
control tension on the safety belt.
- monitors the SRS for faults.
- requests the illumination of the air bag indicator if a fault is detected.
- communicates through the DLC the on-demand or continuous DTCs.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the ON position, the RCM will request illumination of 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 6 seconds and then off. If a SRS fault exists, the air bag indicator will illuminate and
remain illuminated for the rest of the key cycle. The RCM will also communicate the on-demand
(current) and continuous (historical) DTCs through the DLC, to the scan tool. If the RCM requests
illumination of the air bag indicator and the air bag indicator does not function, the instrument
cluster module will automatically activate an audible chime. The chime is a series of 5 sets of 5
tone bursts. If the chime is heard, the SRS and the air bag indicator require repair.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is lost or damaged during impact. The backup
power supply will deplete its stored energy approximately one minute after the battery ground cable
is disconnected.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7626
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
Special Tool(s)
Removal
WARNING:
- Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag
module. This will reduce the risk of injury in the event of an accidental deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be installed new whether or not the air bags have deployed. In addition, make sure the
area of
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7627
the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or
any other damaged SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag RCM retaining nuts is critical for correct system operation.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
can result.
- When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out
programmable module installation (PMI). See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning
NOTE:
- When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect
RCM is installed, erroneous DTCs will result.
- 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 SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
Vehicles built 7/31/06 or after 1. Carry out the steps necessary to prepare for programmable
module installation (PMI).
All vehicles 2. Depower the system. 3. Remove the floor console.
4. Disconnect the large restraints control module (RCM) electrical connector.
1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the
way back until it stops.
2 Pull out and disconnect the large RCM electrical connector.
5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove
the 3 RCM nuts. 7. Remove the RCM.
Installation
All vehicles 1. Install the RCM.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7628
2. Install the 3 RCM nuts.
- Tighten to 12 Nm (9 lb-ft).
3. Connect the small RCM electrical connector.
4. NOTE: The RCM has been removed for clarity.
On the large RCM electrical connector, place the connector position assurance lever in the full
release position.
5. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
Position the large RCM electrical connector into the RCM.
6. Connect the large RCM connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Technical Service Bulletins > Page 7629
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
- Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
7. Install the floor console. 8. Repower the system. Do not prove out the SRS at this time.
Vehicles built 7/31/06 or after 9. Carry out the steps necessary to complete PMI.
All vehicles 10. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams
C2286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams > Page 7633
Air Bag Deactivation Indicator: Description and Operation
PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
The passenger air bag deactivation (PAD) indicator is a visual indicator used to inform the front
seat occupants of the passenger air bag deactivation state. The PAD indicator is a stand-alone
lamp installed into the vehicle instrument panel in a position visible to each front seat occupant.
The RCM controls the state of the PAD indicator through a direct hardware connection, based on
information provided by the occupant classification sensor (OCS) system. The PAD indicator is lit
to indicate the passenger air bag module is disabled. An exemption to this is when the front
passenger seat is determined to be empty and passenger safety belt buckle unbuckled, and
therefore indication of a deactivated passenger air bag module is not necessary. In all other cases,
the PAD indicator is unlit when the passenger air bag module is enabled. When the ignition switch
is in the ON position, the PAD indicator prove-out period is initiated by the RCM. The RCM briefly
activates the PAD indicator to prove-out the indicator function and verify to the front occupants
correct functional operation of the PAD indicator.
The PAD indicator will be lit/unlit within 1.0 to 1.5 seconds of a change of state from the OCS
system.
When an OCS system fault is present, the RCM defaults the passenger air bag module to the last
valid state received from the OCS system until the ignition switch is turned OFF. If the OCS system
fault is still present when the ignition switch is turned ON, the RCM defaults the passenger air bag
module to enabled regardless of the size of occupant in the front passenger seat. The PAD
indicator will be unlit.
Passenger Air Bag And PAD Indicator Status
The above table indicates the passenger air bag status and the PAD indicator status based the
size of the front outboard passenger occupant
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams > Page 7634
Air Bag Deactivation Indicator: Service and Repair
PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Remove the floor console. 3. Gently pull outward to release the clips on
the instrument panel center finish panel. 4. Disconnect the passenger air bag deactivation (PAD)
indicator electrical connector. 5. Remove the 2 screws and remove the PAD indicator. 6. To install,
reverse the removal procedure. 7. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Description
and Operation
Air Bag Resistor: Description and Operation
SAFETY CANOPY BRIDGE RESISTOR
CAUTION: Do not deactivate the driver safety canopy module circuit by removing the bridge
resistor from the electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the
restraints control module (RCM).
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated.
The safety canopy bridge resistor:
- is equipped on vehicles without safety canopy modules.
- must not be removed during deactivation.
- is located on the LH side D-pillar, behind the trim panel on Explorer/Mountaineer and on the LH
side C-pillar, behind the trim panel on Explorer Sport Trac.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Resistor > Component Information > Description
and Operation > Page 7638
Air Bag Resistor: Service and Repair
SAFETY CANOPY BRIDGE RESISTOR
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Remove the driver side upper C-pillar trim panel. 3. Cut the safety
canopy bridge resistor fabric tether close to the rear of the headliner. 4. Disconnect the electrical
connector and remove the safety canopy module bridge resistor.
5. NOTE: The service part comes without the fabric tether. There is no need to connect the service
part to the OEM fabric tether.
To install, reverse the removal procedure.
6. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams
Clockspring Assembly / Spiral Cable: Diagrams
C218A
C218B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7642
Clockspring Assembly / Spiral Cable: Description and Operation
CLOCKSPRING
The clockspring:
- is mounted on the steering column, behind the steering wheel.
- continuously transfers electrical signals from the driver air bag module to the RCM.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7643
Clockspring Assembly / Spiral Cable: Service and Repair
CLOCKSPRING
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7644
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.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Make sure the road wheels are in the straight-ahead position. 3. Tilt the
steering wheel in the downward position and lock the tilt handle. 4. Remove the driver air bag
module. 5. Remove the steering wheel. 6. Remove the 2 screws and the instrument panel (I/P)
lower steering column opening cover. 7. Remove the 3 screws and the lower steering column
shroud. 8. Remove the upper steering column shroud. 9. Disconnect the clockspring electrical
connector.
10. Remove the 2 screws and position aside the steering angle sensor. 11. Remove the 2
clockspring screws and remove the clockspring.
Installation
All vehicles
1. Install the clockspring and the 2 screws. 2. Position the steering angle sensor and install the 2
screws. 3. Connect the clockspring electrical connector. 4. Install the upper steering column
shroud. 5. Install the lower steering column shroud and the 3 screws. 6. Install the I/P lower
steering column opening cover and the 2 screws.
Vehicles installing a new clockspring
7. Install the steering wheel.
- After the steering wheel installation, remove the clockspring sealing key.
Vehicle repairs reusing the same clockspring
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Diagrams > Page 7645
8. WARNING: Incorrect centralization may result in premature component failure. If in doubt when
centralizing the clockspring, repeat
the centralizing procedure. Failure to follow this instruction may result in personal injury.
CAUTION: Make sure the road wheels are in the straight-ahead position.
If the vehicle's clockspring has rotated out of center, follow these steps to center the clockspring.
1 Hold the clockspring outer housing stationary.
2 CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and
can be broken from its internal connection.
While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length and
for a slight resistance. Stop turning at this point.
3 Turn the clockspring clockwise (approximately 2-1/2 turns) until the clockspring rotor wiring and
connector are in the 12'o clock position. Clockspring is now centered. Do not allow the rotor to turn from this position.
9. CAUTION: If the vehicle is left unattended by the technician between centralizing the clockspring
and installing the steering wheel, the
centralizing procedure must be repeated.
Install the steering wheel.
All vehicles
10. Install the driver air bag module. 11. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor, Left/Right
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor, Left/Right > Page 7650
View 151-18 (Left Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor, Left/Right > Page 7651
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor, Left/Right > Page 7652
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Forward Crash Sensor, Left/Right > Page 7653
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor, Left
C1465
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor, Left > Page 7656
C1466
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor, Left > Page 7657
Impact Sensor: Diagrams Side Impact Sensor
C567A
C567B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor, Left > Page 7658
C644A
C644B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Forward Crash Sensor, Left > Page 7659
C3248
C3249
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Page 7660
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed.
In addition, make sure the area of the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct restraint system operation. If a vehicle equipped
with an SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Replace and correctly position the sensor or any other damaged SRS components
whether or not the air bag is deployed.
For these vehicles, the SRS uses up to 6 satellite sensors in addition to the RCM. The RCM is
mounted to the center tunnel beneath the console. All vehicles will have 2 front impact severity
sensors located in the front-center area of the vehicle, behind the grille mounted on the lower
radiator support. The first row impact sensors are located in each of the front doors behind the trim
panel. If the vehicle is equipped with safety canopies, there are 2 additional side impact sensors.
The 2 additional sensors are located on each C-pillar. Mounting orientation and torque is critical for
correct operation of all impact and rollover sensors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor
Impact Sensor: Service and Repair Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
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. Install and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To reduce the risk of 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7663
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Remove the 4 pin-type retainers and the lower radiator air deflector.
3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is
critical for correct system operation.
NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free
of foreign material.
- Note position of locator tab on sensor bracket for installation.
Remove the front impact severity sensor bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Disconnect the front impact severity sensor electrical connector and remove the sensor. 5. To
install, reverse the removal procedure. 6. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7664
Impact Sensor: Service and Repair Side Impact Sensor
C-Pillar
SIDE IMPACT SENSOR - C-PILLAR
Removal and 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Install a new sensor and correctly position the sensor or any other damaged SRS
components whether or not the air bag is deployed.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- RH side shown, LH similar.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7665
- The RH and LH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the system. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip.
4. Remove the 2 lower C-pillar trim panel retaining clips from the rear door opening sheet metal.
5. Position aside the lower C-pillar trim panel.
- Pull out on the quarter trim panel at the C-pillar to release the 3 retaining clips and access the
C-pillar side impact sensor.
6. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for
correct system operation.
NOTE: -
Note the position of the sensor and bracket locating tab for installation.
- Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign
material.
Remove the 2 bolts from the side impact sensor and bracket assembly. To install, tighten to 12 Nm (9 lb-ft).
7. Disconnect the electrical connector and remove the side impact sensor. 8. To install, reverse the
removal procedure. 9. Repower the system.
Front Door
SIDE IMPACT SENSOR - FRONT DOOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7666
Removal and 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Install a new sensor and correctly position the sensor or any other damaged SRS
components whether or not the air bag is deployed.
- 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 SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Driver side shown, passenger side similar.
1. Depower the system. 2. Remove the front interior door trim panel. 3. Detach the rearward lower
corner of the watershield on the door to expose the side impact sensor. 4. Disconnect the side
impact sensor electrical connector.
5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct
system operation.
CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position
the ground wire between the U-nut
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor > Page 7667
and the sensor.
NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material.
- Note the position of the side impact sensor locating tabs for installation.
Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure. 7. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Description and Operation
Seat Occupant Classification Module - Air Bag: Description and Operation
OCS SYSTEM MODULE
Based on programmed limits, the OCS module will inform the RCM, via a High Speed Controller
Area Network (HS-CAN), of the necessary information. The RCM uses this information in
determining if the passenger air bag module or passenger seat side air bag module is to be
deployed in the event of a deployable collision.
The OCS module monitors the OCS system for faults and communicates on-demand and
continuous diagnostic trouble codes (DTCs) via the DLC with the use of a scan tool.
The components that make up the OCS system, OCS system module, inboard OCS rail and
outboard OCS rail are serviced separately.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Description and Operation > Page 7671
Seat Occupant Classification Module - Air Bag: Service and Repair
OCCUPANT CLASSIFICATION MODULE
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Power seat shown, manual similar.
- Seat is removed for clarity.
1. Depower the system. 2. From underneath the front of the seat, disconnect the OCS module
electrical connector.
3. NOTE: Note the position of the locator tab on the OCS module for installation.
Remove the 2 screws and the OCS module. To install, tighten to 2 Nm (18 lb-in).
4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this
time.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Component Information > Description and Operation > Page 7672
6. Carry out the appropriate procedure after installation of an OCS system component.
- If installing the original OCS system component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. See: Testing and
Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS)
System Zero Seat Weight Test
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. See: Service and Repair
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Locations
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Occupant Classification Sensor Module
C3159
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Occupant Classification Sensor Module > Page 7678
C3291
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Diagrams > Occupant Classification Sensor Module > Page 7679
C3292
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > OCS System
Seat Occupant Sensor: Description and Operation OCS System
OCS System
The OCS system is found only on the front passenger seat. The front passenger OCS system is
comprised of the following: 2 OCS rails (weight sensors) that are mounted to each side of the seat
track; an OCS module (electronic control unit) which is mounted to the electrical bracket
underneath the seat cushion pan. The weight of any occupant or object on the front passenger seat
is electronically communicated to the OCS module.
The OCS system is also used for operation of the passenger Belt Minder. To deactivate or
reactivate the passenger Belt Minder feature, refer to Seat Belt Systems or the owner's literature.
The components that make up the OCS system, OCS module, inboard OCS rail and outboard OCS
rail are serviced separately.
When the front passenger seat is removed for service, the Zero Seat Weight Test must be carried
out after the installation of the front passenger seat. When a OCS system component is installed
new, the System Reset must be carried out after the installation of the front passenger seat. The
Zero Seat Weight Test and/or System Reset must be carried out only as instructed to do so.
OCS Rails (Weight Sensors)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > OCS System > Page 7682
The components that make up the OCS system (OCS system module, inboard OCS rail and
outboard OCS rail) are serviced separately.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > OCS System > Page 7683
Seat Occupant Sensor: Description and Operation Occupant Classification Sensor (OCS) System
OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM
The occupant classification system (OCS) system is standard equipment on all front passenger
seats.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > Page 7684
Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > Page 7685
Part 2
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.
- The occupant classification sensor rails have a built-in strain gauge which may operate incorrectly
if an occupant classification sensor rail is dropped by itself, dropped when installed to the front
passenger seat or dropped when installed to a front passenger seat track assembly. Use care
when handling an occupant classification sensor rail or when installed to the front passenger seat
of front passenger seat track assembly. Failure to follow these instructions may increase the risk of
personal injury or death in a crash.
- Do not disassemble the occupant classification sensor rail, tighten or loosen any of the nuts and
bolts installed to the occupant classification sensor rail body. Only the 8 bolts that attach the 2
occupant classification sensor rails to the seat track should be removed and installed. Failure to
follow these instructions may increase the risk of personal injury or death in a crash.
- Oil, grease, water or foreign material on or in the occupant classification sensor rail may cause
the supplemental restraint system to deploy incorrectly. Never allow oil, grease, water or foreign
material to get on or into the occupant classification sensor rail. Failure to follow these instructions
may increase the risk of personal injury or death in a crash.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- 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.
- Outboard occupant classification sensor (OCS) rail shown, inboard similar.
1. Remove the passenger seat and depower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > Page 7686
2. CAUTION: Push only on the tip of the occupant classification sensor (OCS) electrical connector
release tab to release the electrical
connector. Do not insert the tool too deep into the OCS electrical connector or damage to the
electrical connector may occur.
NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring
retainers for installation.
On the affected side, detach the 2 OCS rail wiring retainers. Then using a suitable tool, release the
tab and disconnect the OCS rail electrical connector.
3. If equipped, disconnect the power seat track motor electrical connector.
4. Move the seat to the forward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Remove the 2 rear bolts from the affected OCS rail.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > Page 7687
6. Move the seat to the rearward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail
shield and into the rear mounting point of the seat
track for installation.
Remove the 2 front bolts and the affected OCS rail and shield.
Installation
NOTE: If installing a new seat track, position the seat track where the seat will be in the rearward
most position before starting installation of the OCS rails.
1. WARNING: The occupant classification sensor rail shield is an aid to prevent foreign material
and contaminants from entering the
occupant classification sensor rail. Make sure the occupant classification sensor rail shield is
present, is not damaged and is correctly installed to the occupant classification sensor rail. Failure
to follow these instructions may increase the risk of personal injury or death in a crash.
NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to
the shield.
Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat
track while noting the correct installation of the OCS rail locator tab into the seat track.
2. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence
shown.
While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position
rear bolt. Tighten to 25 Nm (18 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Description and Operation > Page 7688
3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting
position front bolt.
- Tighten to 25 Nm (18 lb-ft).
4. Move the seat to the forward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Install the 2 rear OCS rail bolts.
- Tighten to 25 Nm (18 lb-ft).
6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during
removal.
Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring
retainers.
7. Center the seat track to the seat cushion pan.
- If equipped with a power seat track, apply power and ground to the pins shown.
8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger
seat and repower the supplemental restraints system (SRS). Do not prove out the SRS at this time.
10. Carry out the appropriate procedure after installation of an OCS system component.
- If installing the original OCS system component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. See: Testing and
Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS)
System Zero Seat Weight Test
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. See: Service and Repair
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Service and Repair
Seat Position Sensor: Service and Repair
SEAT POSITION SENSOR
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Power seat track seat position sensor shown, manual seat track position sensor similar.
1. Position the front seat to the rearmost and upward position. 2. Depower the system. 3.
Disconnect the seat position sensor electrical connector.
4. WARNING: The tightening torque of the seat position sensor retaining bolt is critical for correct
system operation.
NOTE: Note the position of the seat position sensor locating tab for installation.
Remove the bolt and the seat position sensor. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Service and Repair > Page 7692
6. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description
and Operation
Side Air Bag: Description and Operation
Driver Seat Side Air Bag Module
NOTE:
- References to seat side air bag modules refer to the seat-mounted and not to the steering wheel
or instrument panel mounted air bag components of the SRS.
- When servicing a seat equipped with a seat side air bag module, refer to Seats.
A seat side air bag module provides protection of the thorax area (between the neck and abdomen)
of the body, working in conjunction with the head protection provided by a safety canopy module (if
equipped).
The driver seat side air bag module: will deploy upon receiving a flow of current from the RCM initiated by the driver side impact sensor
and internal RCM circuitry.
- is installed as an assembly.
- is mounted in the driver seat back.
- is used in conjunction with a safety canopy module (if equipped).
Passenger Seat Side Air Bag Module
NOTE:
- References to seat side air bag modules refer to the seat-mounted and not to the steering wheel
or instrument panel mounted air bag components of the SRS.
- When servicing a seat equipped with a seat side air bag module, refer to Seats.
A seat side air bag module provides protection of the thorax area (between the neck and abdomen)
of the body, working in conjunction with the head protection provided by a safety canopy module (if
equipped).
The passenger seat side air bag module: will deploy upon receiving a flow of current from the RCM initiated by the passenger side impact
sensor and internal RCM circuitry.
- is installed as an assembly.
- is mounted in the passenger seat back.
- is used in conjunction with a safety canopy module (if equipped).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description
and Operation > Page 7696
Side Air Bag: Service and Repair
SIDE AIR BAG MODULE
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live side air bag module with the air bag and tear seam pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Side air bag modules with damaged covers must be installed new.
- Front seat back trim covers installed on seats equipped with side air bags cannot be repaired,
they are to be replaced. Cleaning is permissible.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
NOTE:
- If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module
must be installed. 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.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description
and Operation > Page 7697
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Driver seat side air bag module shown, passenger side similar.
1. Remove the front seat and depower the system. 2. Remove the seat backrest.
3. NOTE: RH shown, LH similar.
Remove the 2 plastic rivets attaching the backrest trim cover to the inboard and outboard recliners
on the seat backrest frame.
4. Release the seat back lower outer trim cover J-clip.
5. Release the seat back lower inner trim cover J-clip.
6. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be
repaired; they are to be installed new
(cleaning is permissible).
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.
Place a hand between the seat backrest trim cover and foam pad and carefully separate the
hook-and-loop strips, then carefully roll up the seat back trim cover in an inside out fashion to the
first row of hog rings in the front.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description
and Operation > Page 7698
7. Remove the first row of hog rings. 8. Detach the hook-and-loop strips and invert the seat
backrest trim cover up enough to expose the side air bag.
9. NOTE: Note the position and the routing of the side air bag module wiring harness for
installation.
Detach the side air bag wiring harness retainers from the seat backrest frame.
10. Position out the seat backrest foam pad. 11. Remove the 2 bolts and the side air bag module.
Installation
WARNING:
- Inspect the mounting surfaces of the side air bag module and the seat back frame mounting
bracket for any foreign material before installing the side air bag module. If any foreign material is
found, remove it. 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 material. If the air bag
module is damaged, install a new module. If any foreign material is found, remove it. Failure to do
so may result in personal injury, in the event of an air bag deployment.
- Inspect the side air bag cavity in the seat back pad for any foreign material. If any foreign material
is found, remove it. Failure to do so may result in personal injury in the event of an air bag
deployment.
- If the air bag cover has separated or the air bag material has been exposed, install a new side air
bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal
injury in the event of an air bag deployment.
CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air
bag module and the backrest frame.
All seats
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description
and Operation > Page 7699
1. Align the holes of the side air bag module bracket to the U-nuts on the backrest frame.
- Install new U-nuts if installing a new side air bag module.
2. Slide the side air bag module onto the backrest frame so the bracket hook wraps around the
backrest frame. 3. Install the side air bag module and the bolts.
- Tighten to 10 Nm (89 lb-in).
4. Position back the seat backrest foam pad.
5. Attach the side air bag wiring harness retainers to the seat backrest frame.
6. Attach the hook-and-loop strips, and roll the seat back trim cover down and install the first row of
hog rings.
7. Attach the hook-and-loop strips, and roll the seat back trim cover down and attach the seat back
lower inner trim cover J-clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Description
and Operation > Page 7700
8. Attach the seat back lower outer trim cover J-clip.
9. NOTE: RH shown, LH similar.
Fold the backrest trim cover over on each side of the inboard and outboard recliner. Install the
plastic rivets attaching the backrest trim cover to the inboard and outboard recliners on the seat
backrest frame.
10. Install the seat backrest. 11. Install the passenger seat and repower the supplemental restraints
system (SRS). Do not prove out the SRS at this time.
Passenger seat 12. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight
Test and prove out the SRS. See: Testing and
Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS)
System Zero Seat Weight Test
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7706
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7707
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7708
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7709
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7710
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7711
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
7712
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7713
Air Bag Control Module: Locations
View 151-15 (Center Console)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7714
View 151-17 (Right Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7715
Air Bag Control Module: Diagrams
C310A
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7716
C310B (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7717
C310B (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7718
Air Bag Control Module: Description and Operation
RESTRAINTS CONTROL MODULE (RCM)
WARNING:
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed.
In addition, make sure the area of the RCM mounting is restored to its original condition.
CAUTION: When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry
out programmable module installation (PMI).
NOTE: When installing a new RCM, always make sure the correct RCM is being installed. If an
incorrect RCM is installed, erroneous DTCs will result.
The RCM carries out the following functions:
- deploys the air bag(s) in the event of a deployable crash.
- activates the safety belt buckle pretensioner and safety belt adaptive load limiting retractor to
control tension on the safety belt.
- monitors the SRS for faults.
- requests the illumination of the air bag indicator if a fault is detected.
- communicates through the DLC the on-demand or continuous DTCs.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the ON position, the RCM will request illumination of 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 6 seconds and then off. If a SRS fault exists, the air bag indicator will illuminate and
remain illuminated for the rest of the key cycle. The RCM will also communicate the on-demand
(current) and continuous (historical) DTCs through the DLC, to the scan tool. If the RCM requests
illumination of the air bag indicator and the air bag indicator does not function, the instrument
cluster module will automatically activate an audible chime. The chime is a series of 5 sets of 5
tone bursts. If the chime is heard, the SRS and the air bag indicator require repair.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is lost or damaged during impact. The backup
power supply will deplete its stored energy approximately one minute after the battery ground cable
is disconnected.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7719
Air Bag Control Module: Service and Repair
RESTRAINTS CONTROL MODULE (RCM)
Special Tool(s)
Special Tool(s)
Removal
WARNING:
- Always wear safety glasses when repairing an air bag SRS vehicle and when handling an air bag
module. This will reduce the risk of injury in the event of an accidental deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- The RCM orientation is critical for correct air bag supplemental restraint system (SRS) operation.
If a vehicle equipped with an SRS system has been involved in a collision in which the center
tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the
RCM must be installed new whether or not the air bags have deployed. In addition, make sure the
area of
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7720
the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting
bracket and wiring pigtail for deformation. Install a new sensor and correctly position the sensor or
any other damaged SRS components whether or not the air bag is deployed.
- The tightening torque of the air bag RCM retaining nuts is critical for correct system operation.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION:
- Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage
can result.
- When installing a new RCM on vehicles built 7/31/06 or after, it is necessary to carry out
programmable module installation (PMI). See: Powertrain Management/Computers and Control
Systems/Information Bus/Testing and Inspection/Programming and Relearning
NOTE:
- When installing a new RCM, always make sure the correct RCM is being installed. If an incorrect
RCM is installed, erroneous DTCs will result.
- 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 SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
Vehicles built 7/31/06 or after 1. Carry out the steps necessary to prepare for programmable
module installation (PMI).
All vehicles 2. Depower the system. 3. Remove the floor console.
4. Disconnect the large restraints control module (RCM) electrical connector.
1 Pinch the thumb tab and pivot the large RCM electrical connector position assurance lever all the
way back until it stops.
2 Pull out and disconnect the large RCM electrical connector.
5. Press to release the locking tab and disconnect the small RCM electrical connector. 6. Remove
the 3 RCM nuts. 7. Remove the RCM.
Installation
All vehicles 1. Install the RCM.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Technical Service Bulletins > Page 7721
2. Install the 3 RCM nuts.
- Tighten to 12 Nm (9 lb-ft).
3. Connect the small RCM electrical connector.
4. NOTE: The RCM has been removed for clarity.
On the large RCM electrical connector, place the connector position assurance lever in the full
release position.
5. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad
electrical connections and damage
components.
Position the large RCM electrical connector into the RCM.
6. Connect the large RCM connector.
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Component Information > Technical Service Bulletins > Page 7722
- CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure
is needed to get the connector into position on the RCM before using the lever to fully seat the
connector.
With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle
audible click is heard and a slight resistance is felt.
- Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into
the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
7. Install the floor console. 8. Repower the system. Do not prove out the SRS at this time.
Vehicles built 7/31/06 or after 9. Carry out the steps necessary to complete PMI.
All vehicles 10. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
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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
7727
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
7728
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7729
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7730
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7731
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
7732
^ View and Record DTC XXXXX Fault PIDs (2007 WSM)
^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs)
In each instance the direction is the same (view fault PIDs to identify the specific component and
fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology,
will vary.
FLAG the DTC - View the Fault PIDs
For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is
necessary to view the fault PIDs from DataLogger.
Using IDS/PDS
NOTE
WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO
DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS,
HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION.
1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous
memory DTCs.
2. To view the fault PIDs associated with an on-demand DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads
"FAULT' indicating a front internal crash sensor fault.
4. To view the fault PIDs associated with a continuous memory DTC:
a. Toolbox
b. DataLogger
c. Modules
d. RCM
5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that
reads "FAULT".
For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads
"FAULT" indicating a front internal crash sensor fault.
IDS/PDS Fault PID Naming Conventions
The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example,
the fault PIDs 2296_18_OD and 2296_18_CM break down as follows:
^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation.
^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC.
^ OD - Identifies the fault PID as an on-demand fault.
^ CM - Identifies the fault PID as a continuous memory (intermittent) fault.
NOTE
THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON
VEHICLE EQUIPMENT.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module >
Component Information > Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page
7733
Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5)
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Description and Operation
Seat Occupant Classification Module - Air Bag: Description and Operation
OCS SYSTEM MODULE
Based on programmed limits, the OCS module will inform the RCM, via a High Speed Controller
Area Network (HS-CAN), of the necessary information. The RCM uses this information in
determining if the passenger air bag module or passenger seat side air bag module is to be
deployed in the event of a deployable collision.
The OCS module monitors the OCS system for faults and communicates on-demand and
continuous diagnostic trouble codes (DTCs) via the DLC with the use of a scan tool.
The components that make up the OCS system, OCS system module, inboard OCS rail and
outboard OCS rail are serviced separately.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Description and Operation > Page 7737
Seat Occupant Classification Module - Air Bag: Service and Repair
OCCUPANT CLASSIFICATION MODULE
Removal
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Power seat shown, manual similar.
- Seat is removed for clarity.
1. Depower the system. 2. From underneath the front of the seat, disconnect the OCS module
electrical connector.
3. NOTE: Note the position of the locator tab on the OCS module for installation.
Remove the 2 screws and the OCS module. To install, tighten to 2 Nm (18 lb-in).
4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this
time.
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Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Description and Operation > Page 7738
6. Carry out the appropriate procedure after installation of an OCS system component.
- If installing the original OCS system component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and
Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS)
System Zero Seat Weight Test
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. See: Air Bag Systems/Service and Repair
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Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Special Tool(s)
Special Tool(s)
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box
(SJB), located below the LH side of the instrument panel, remove the cover and the restraints
control module (RCM)
fuse 17 (10A) from the SJB.
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 switch to OFF.
6. WARNING: To avoid accidental deployment and possible personal 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
servicing, 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.
The front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
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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.
2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the
cover.
4. 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.
5. Prove out the SRS as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
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Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7745
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment, which can result in personal injury.
- The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always
wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never
probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in
pretensioner, adaptive load limiting retractor or air bag deployment and could 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 reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
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Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7746
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart
junction box (SJB), located below the LH side of the instrument panel, remove the cover and the
restraints control module (RCM)
fuse 17 (10A) from the SJB.
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 front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
7. Remove the 2 driver air bag module bolts (1 shown).
8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation.
Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7747
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
10. Open and lower the glove compartment door.
11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield.
12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive
tether squibs do not require deactivation.
Through the glove compartment opening, disconnect the LH side passenger air bag module
electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector on the LH side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7748
14. From under the rear of the passenger seat, detach the passenger seat side air bag module
electrical connector from the seat track bracket. Then
slide and disengage the passenger seat side air bag module electrical connector locking clip, and
then release the tab and disconnect the passenger seat side air bag module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Vehicles without safety canopy modules
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM.
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Explorer and Mountaineer vehicles with safety canopy modules
17. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7749
18. Disconnect the passenger side safety canopy module electrical connector.
19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
20. Release and position aside the driver side C-pillar trim panel.
21. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7750
22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles with safety canopy modules
23. Remove the driver and passenger side upper C-pillar trim panels.
24. Disconnect the passenger side safety canopy module electrical connector.
25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
26. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7751
27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles
28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module
electrical connector locking clip, and then release
the tab and disconnect the driver seat side air bag module electrical connector.
29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the
battery ground cable.
Reactivation
All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7752
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side
air bag module electrical connector.
4. Connect the driver seat side air bag module electrical connector and then slide and engage the
seat side air bag electrical connector locking clip.
Explorer Sport Trac vehicles with safety canopy modules
5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
6. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7753
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy module electrical connector.
8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and
passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles with safety canopy modules
10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
11. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7754
12. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
side safety canopy module electrical connector.
14. Connect the passenger side safety canopy module electrical connector.
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7755
16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
seat side air bag module electrical connector.
17. Connect the passenger seat side air bag module electrical connector and then slide and
engage the seat side air bag electrical connector locking
clip. Then attach the passenger seat side air bag module electrical connector to the seat track
bracket.
18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector on the LH side.
19. Connect the LH side passenger air bag module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7756
20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21.
Close glove compartment door.
22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the
driver air bag module in the wrong
position. Match the electrical connector key to the keyway in the driver air bag module. Do not force
the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted in removal.
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 7757
25. 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.
26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and
install the cover.
28. 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.
29. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch back to ON and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a
scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Description and Operation
Child Seat Tether Attachment: Description and Operation
Child Safety Seat Tether Anchors
WARNING: The child safety seat tether anchor/bolt MUST be securely tightened to specification.
Otherwise, the child safety seat may not be correctly secured and the child could be injured if the
vehicle is involved in a collision or stops suddenly.
The second row outboard child safety seat tether anchors for a 5-passenger vehicle are located
directly behind the seat, attached to the floor pan protruding from the carpet. Either of the tether
anchors for a 5-passenger vehicle located near the back hatch door can be used for the second
row center child safety seat tether anchor. There are also 2 child safety seat tether anchors/cargo
tie downs located in the scuff plate at the back edge of the door.
The 3 second row seats of a 7-passenger vehicle have child safety seat tether anchors that are
located directly behind the second row seats attached to the floor pan, protruding from the carpet.
The 2 third row child safety seat tether anchors are located directly behind the seat near the back
hatch door.
If the child safety seat tether anchors were in use during a collision, inspect and install new anchors
as necessary. Return the vehicle structure to its original production configuration.
Lower Anchors And Tethers For Children (LATCH)
The lower anchors and tethers for children (LATCH) system is a standardized and uniform
attachment system for installing child safety seats in passenger vehicles. LATCH-equipped child
safety seats have 2 lower attachments that connect to the vehicle portion of the LATCH system.
The vehicle portion of the system consists of 2 attachment points (6-mm wires) welded to the seat
cushion frame. The attachment points protrude from the biteline between the seat cushion and seat
backrest at the second row outboard seating positions.
If a child safety seat was in use during a collision, inspect the vehicle portion of the system for
damage. If any of the attachment points (6-mm wires) are damaged, install a new seat cushion
frame.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row
Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Second Row
CHILD SAFETY SEAT TETHER ANCHOR - SECOND ROW
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
NOTE:
- Second row bucket seats shown, others similar.
- Carpet removed for clarity.
1. Remove the bolt(s) and tether anchor(s).
- To install, tighten to 40 Nm (30 lb-ft).
2. NOTE: Sealant must be applied to the tether anchor bolts when installed.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row > Page 7764
Child Seat Tether Attachment: Service and Repair Child Safety Seat Tether Anchor - Third Row
CHILD SAFETY SEAT TETHER ANCHOR - THIRD ROW
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
1. Remove the liftgate scuff plate trim panel. 2. Remove the tether anchor bolt(s) and tether
anchor(s).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Service and Repair > Child Safety Seat Tether Anchor - Second Row > Page 7765
- To install, tighten to 40 Nm (30 lb-ft).
3. NOTE: Sealant must be applied to the tether anchor bolts when installed.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Description and
Operation
Seat Belt: Description and Operation
SAFETY BELT EXTENSION ASSEMBLY
In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in)
can be added to the belt length by using a safety belt extension. Safety belt extensions are
available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt
extensions are only available with black webbing.
Use only extensions manufactured by the same supplier as the safety belt. Manufacturer
identification is located at the end of the webbing on the label. Also, use the safety belt extension
only if the safety belt is too short for you when fully extended. Do not use an extension to change
the fit of the shoulder belt across the torso.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Diagrams > Safety Belt Buckle Pretensioner, Driver
C3201
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Diagrams > Safety Belt Buckle Pretensioner, Driver > Page 7773
C3202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Diagrams > Page 7774
Seat Belt Buckle: Description and Operation
SAFETY BELT BUCKLE AND PRETENSIONER
The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from
the safety belt when deployed. The pretensioner works in conjunction with the front air bag system.
When the front air bags deploy, the pretensioners deploy, causing the buckle to move downward,
removing excess webbing from the lap and shoulder safety belts.
If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt
pretensioners, a new driver and passenger seat belt system (including safety belt buckle and
pretensioners, safety belt retractors and height adjusters) must be installed.
For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems.
For safety belt buckle pretensioner disposal information, refer to Air Bag Systems.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Bucket
SAFETY BELT BUCKLE - SECOND ROW, BUCKET
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
1. Tilt the second row seat forward. 2. Remove the bolt and safety belt buckle.
- To install, tighten to 47 Nm (35 lb-ft).
3. NOTE: Sealant must be applied to the safety belt buckle bolt when installed.
To install, reverse the removal procedure.
4. Check the active restraint system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7777
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Center and RH, 60/40,
Bench
SAFETY BELT BUCKLE - SECOND ROW, CENTER AND RH, 60/40, BENCH
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
NOTE: Seat cushion removed for clarity.
1. Remove the 2 bolts and dual safety belt buckle.
- To install, tighten to 40 Nm (30 lb-ft).
2. To install, reverse the removal procedure. 3. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7778
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Center and RH, 60/40, E-Z
Entry
SECOND ROW, CENTER AND RH, 60/40, E-Z ENTRY
Removal and Installation
WARNING: All safety belt assemblies (including retractors, buckles, belt tension sensors [BTS] if
equipped, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
NOTE: Seat is removed from the vehicle for clarity.
1. Remove the 2 bolts and dual safety belt buckle assembly.
- To install, tighten to 40 Nm (30 lb-ft).
2. To install, reverse the removal procedure. 3. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7779
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, LH, 60/40, Bench
SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, BENCH
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
1. Remove the 40 percent seat from the vehicle. 2. Remove the bolt and safety belt buckle.
- To install, tighten to 55 Nm (41 lb-ft).
3. To install, reverse the removal procedure. 4. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7780
Seat Belt Buckle: Service and Repair
Safety Belt Buckle - Second Row, Bucket
SAFETY BELT BUCKLE - SECOND ROW, BUCKET
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
1. Tilt the second row seat forward. 2. Remove the bolt and safety belt buckle.
- To install, tighten to 47 Nm (35 lb-ft).
3. NOTE: Sealant must be applied to the safety belt buckle bolt when installed.
To install, reverse the removal procedure.
4. Check the active restraint system for correct operation.
Safety Belt Buckle - Second Row, Center and RH, 60/40, Bench
SAFETY BELT BUCKLE - SECOND ROW, CENTER AND RH, 60/40, BENCH
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7781
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
NOTE: Seat cushion removed for clarity.
1. Remove the 2 bolts and dual safety belt buckle.
- To install, tighten to 40 Nm (30 lb-ft).
2. To install, reverse the removal procedure. 3. Check the active restraint system for correct
operation.
Safety Belt Buckle - Second Row, Center and RH, 60/40, E-Z Entry
SECOND ROW, CENTER AND RH, 60/40, E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7782
Removal and Installation
WARNING: All safety belt assemblies (including retractors, buckles, belt tension sensors [BTS] if
equipped, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
NOTE: Seat is removed from the vehicle for clarity.
1. Remove the 2 bolts and dual safety belt buckle assembly.
- To install, tighten to 40 Nm (30 lb-ft).
2. To install, reverse the removal procedure. 3. Check the active restraint system for correct
operation.
Safety Belt Buckle - Second Row, LH, 60/40, Bench
SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, BENCH
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7783
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
1. Remove the 40 percent seat from the vehicle. 2. Remove the bolt and safety belt buckle.
- To install, tighten to 55 Nm (41 lb-ft).
3. To install, reverse the removal procedure. 4. Check the active restraint system for correct
operation.
Safety Belt Buckle - Second Row, LH, 60/40, E-Z Entry
SAFETY BELT BUCKLE - SECOND ROW, LH, 60/40, E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7784
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
1. Tilt the seat forward. 2. Remove the 2 screws and inboard side shield. 3. Remove the bolt and
safety belt buckle.
- To install, tighten to 55 Nm (41 lb-ft).
4. To install, reverse the removal procedure. 5. Check the active restraint system for correct
operation.
Safety Belt Buckle - Third Row
SAFETY BELT BUCKLE - THIRD ROW
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7785
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
NOTE: Power seat shown, manual similar.
1. Remove the RH third row seat. 2. Remove the nut and dual safety belt buckle assembly.
- To install, tighten to 75 Nm (55 lb-ft).
3. To install, reverse the removal procedure. 4. Check the active restraint system for correct
operation.
Safety Belt Buckle and Pretensioner
SAFETY BELT BUCKLE AND PRETENSIONER
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7786
Removal and Installation
WARNING:
- All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles,
shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching
hardware) should be inspected after any collision. All new belt assemblies should be installed
unless a qualified technician finds the assemblies show no damage and operate correctly. Belt
assemblies not in use during a collision should also be inspected and new assemblies installed if
either damage or incorrect operation is noted. Failure to follow these instructions could increase the
risk of injury in collisions.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- LH shown, RH similar.
All seats
NOTE: If equipped with power seats, position the passenger seat track downward to access the
safety belt retractor anchor bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Second Row, Bucket > Page 7787
1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and
allows access to all 4 seat-to-floor fasteners. 2. Remove the affected seat and depower the SRS. 3.
Remove the safety belt buckle pretensioner electrical connector cover. 4. Disconnect the safety
belt buckle electrical connectors. 5. Remove the 2 nuts and safety belt buckle pretensioner.
- To install, tighten to 36 Nm (27 lb-ft).
6. To install, reverse the removal procedure. 7. Install the affected seat and repower the SRS. If the
passenger seat has been serviced, do not prove out the SRS at this time.
Passenger seat
8. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. See: Air Bag Systems/Testing and
Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS)
System Zero Seat Weight Test
All seats
9. Check the active restraint system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Safety Belt Buckle Switch, Passenger
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations > Safety Belt Buckle Switch, Passenger > Page 7792
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Safety Belt Buckle Switch, Driver
C3065
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Safety Belt Buckle Switch, Driver > Page 7795
C3066
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Diagrams > Page 7796
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the SRS, the front safety belt buckles are equipped with safety belt buckle switches. The
safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The
safety belt buckle switches (Hall-effect sensors) are located in the driver and front passenger safety
belt buckles. The safety belt buckle switches indicate to the RCM whether the safety belts are
buckled or unbuckled. The RCM uses this information in determining the deployment rate of the
dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety
belt buckle switch status to the instrument cluster module, which monitors the information to control
the safety belt warning indicator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs
Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs &
Associated Fault PIDs
TSB 07-12-3
06/25/07
RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS)
- SERVICE TIPS
FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred,
Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac
2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar
2005-2007 Escape Hybrid, Escape 2007 E-Series
LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator
2003-2007 Navigator 2006-2007 Mark LT
MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan
2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid
This article supersedes TSB 07-7-8 to update the vehicle application.
ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report
diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require
accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most
2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS)
terminology and navigation which does not translate well when using Integrated Diagnostic System
(IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS).
ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool
being used.
SERVICE TIPS
DTCs And Associated Fault PIDs Description
Many of the continuous memory and on-demand DTCs that can be present in the RCM provide
general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to
identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional
DTCs.
Conventional DTCs identify a specific concern for a given component and point to a particular
diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7801
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7802
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7803
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7804
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7805
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7806
^ 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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information >
Technical Service Bulletins > Restraints - Control Module DTCs & Associated Fault PIDs > Page 7807
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 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair
Seat Belt Height Adjuster: Service and Repair
SAFETY BELT SHOULDER HEIGHT ADJUSTER
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted. Failure to follow these instructions could increase
the risk of injury in collisions.
1. NOTE: Inspect the D-ring cover for damage. If the cover is damage or does not remain attached,
install a new D-ring cover.
Remove the D-ring cover.
2. Remove the bolt and D-ring.
- To install, tighten to 48 Nm (35 lb-ft).
3. Remove the upper B-pillar trim panel. 4. Lower the shoulder safety belt height adjuster to the
most downward position. 5. Remove the bolt.
- To install, tighten to 40 Nm (30 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Page 7811
6. Remove the safety belt shoulder height adjuster.
1 Rotate the safety belt shoulder height adjuster downward to release the lower tab.
2 Remove the safety belt shoulder height adjuster.
7. To install, reverse the removal procedure. 8. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Description and Operation
Seat Belt Reminder Lamp: Description and Operation
Safety Belt Warning Indicator And Chime
The warning indicator and chime are reminders to fasten the safety belt. The system operates as
follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START
position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds.
- If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the
indicator and chime will turn off.
- If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator
nor the chime will turn on.
Belt Minder
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled
by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument
cluster.
To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's
literature.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Description and Operation > Safety Belt Systems
Seat Belt Retractor: Description and Operation Safety Belt Systems
Safety Belt Adaptive Load Limiting Retractor
This vehicle is equipped with a driver and front passenger adaptive load limiting retractors.
Adaptive load limiting retractors are pyrotechnic devices integrated to the driver and front
passenger safety belt retractor assemblies. Adaptive load limiting retractors work in conjunction
with the safety belt buckle pretensioners to control the tension of the driver and front passenger
safety belts. The RCM monitors the readiness of the adaptive load limiting retractor. The RCM uses
this information and all other information provided by the restraints system to determine what action
to be taken.
Dual Locking Mode Retractors
WARNING: After any vehicle collision, the safety belt system at all outboard seating positions
(except driver, which has no automatic locking retractor [ALR] feature) must be checked by a
qualified technician to verify that the ALR feature for child seats is still functioning correctly, in
addition to other checks for correct safety belt system function. A new belt and retractor assembly
must be installed if the safety belt assembly's ALR feature or any other safety belt function is not
operating correctly when checked according to the procedures. Failure to install a new belt and
retractor assembly could increase the risk of injury in collisions.
NOTE: When installing a dual locking mode retractor, the retractor should be checked to make sure
it is not in the automatic locking retractor (ALR) mode after installation in the stowed position.
All outboard continuous-loop, 3-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 safety seat in an outboard seating position or when a tight belt fit is
desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor.
The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and
then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound
is made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged
when most of the webbing is retracted back onto the spool.
The automatic locking mode must be used when installing a child safety seat in the front or rear
passenger seating positions where dual locking mode retractors are provided.
Energy Management Retractor
This vehicle has a safety belt system with an energy management feature at the front seating
positions to help further reduce the risk of injury in the event of a head-on collision.
The energy management retractor feature is designed to pay out webbing in a controlled manner.
This feature is designed to help reduce the belt force acting on an occupant's chest.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Description and Operation > Safety Belt Systems > Page 7819
Seat Belt Retractor: Description and Operation Supplemental Restraint System
ADAPTIVE LOAD LIMITING SAFETY BELT RETRACTOR
This vehicle is equipped with driver and passenger adaptive load limiting retractors. Adaptive load
limiting retractors are pyrotechnic devices integrated to the driver and passenger safety belt
retractor assemblies. Adaptive load limiting retractors work in conjunction with the safety belt
buckle pretensioners and control the tension of the driver and passenger seat belts in the event of
a deployable collision. The RCM monitors the readiness of the adaptive load limiting retractors. The
RCM uses this information and all other information provided by the restraints system to determine
what action is to be taken.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Front
SAFETY BELT RETRACTOR - FRONT
Removal and Installation
WARNING:
- All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles,
shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching
hardware) should be inspected after any collision. All new belt assemblies should be installed
unless a qualified technician finds the assemblies show no damage and operate correctly. Belt
assemblies not in use during a collision should also be inspected and new assemblies installed if
either damage or incorrect operation is noted.
The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a
qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in
addition to other checks for correct safety belt system function. A new belt
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7822
and retractor assembly must be installed if the safety belt assembly's ALR feature or any other
safety belt function is not operating correctly when inspected according to the functional inspection
procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in
collisions.
- The safety belt retractor is a pyrotechnic device. Always wear safety glasses when repairing an
air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- LH shown, RH similar.
1. If equipped with power seats, position the passenger seat track downward to access the safety
belt retractor anchor bolt. 2. Depower the SRS.
3. Remove the safety belt anchor cover from the side of the seat. 4. Remove the bolt and safety
belt anchor.
- To install, tighten to 40 Nm (30 lb-ft).
5. NOTE: If the D-ring cover is damaged or does not remain attached, install a new D-ring cover.
Remove the D-ring cover.
6. Remove the bolt and D-ring.
- To install, tighten to 48 Nm (35 lb-ft).
7. Remove the upper and lower B-pillar trim panels. 8. Remove the secondary safety belt guide. 9.
Disconnect the electrical connector.
10. Remove the bolt and safety belt retractor.
- To install, tighten to 40 Nm (30 lb-ft).
11. To install, reverse the removal procedure. 12. Repower the SRS. 13. Check the active restraint
system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7823
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center, 60/40, Bench
SAFETY BELT RETRACTOR - SECOND ROW, CENTER, 60/40, BENCH
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted.
The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a
qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in
addition to other checks for correct safety belt system function. A new belt and retractor assembly
must be installed if the safety belt assembly's ALR feature or any other safety belt function is not
operating correctly when inspected according to the functional inspection procedures. Failure to
install a new belt and retractor assembly could increase the risk of injury in collisions.
1. Remove the second row, 40 percent seat. 2. Remove the bolt and safety belt anchor.
- To install, tighten to 75 Nm (55 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7824
3. NOTE: LH shown, RH similar.
Remove the 4 screws and position aside the latch covers.
4. Remove the safety belt guide cover. 5. Release the J-clip at the bottom of the seat backrest.
6. Remove all the staples in the backrest support panel.
7. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
seat backrest foam pad.
Separate the hook-and-loop fasteners. Invert the seat backrest trim cover and position aside.
8. Position aside the backrest foam pad. 9. Remove the safety belt retractor cover.
10. Remove the bolt and safety belt retractor.
- To install, tighten to 75 Nm (55 lb-ft).
11. To install, reverse the removal procedure. 12. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7825
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Center, 60/40, E-Z
Entry
SAFETY BELT RETRACTOR - SECOND ROW, CENTER, 60/40, E-Z ENTRY
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted.
The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a
qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in
addition to other checks for correct safety belt system function. A new belt and
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7826
retractor assembly must be installed if the safety belt assembly's ALR feature or any other safety
belt function is not operating correctly when inspected according to the functional inspection
procedures. Failure to install a new belt and retractor assembly could increase the risk of injury in
collisions.
NOTE: Seat is removed and exploded for clarity.
1. Fold the seat and tilt to the E-Z entry position. 2. Remove the 3 screws and inboard recliner
outer cover side shield. 3. Remove the bolt and safety belt anchor.
- To install, tighten to 55 Nm (41 lb-ft).
4. Release the backrest trim cover retainers. 5. Remove the safety belt bezel.
6. NOTE: Use care when separating the seat back trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the backrest
foam pad.
Invert the backrest trim cover.
7. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the hook-and-loop strips.
8. Remove the pin-type retainer and safety belt retractor cover and insulator. 9. Remove the bolt
and safety belt retractor.
- To install, tighten to 75 Nm (55 lb-ft).
10. To install, reverse the removal procedure. 11. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7827
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Outboard
SAFETY BELT RETRACTOR - SECOND ROW, OUTBOARD
Explorer/Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7828
Explorer Sport Trac
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted.
The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a
qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in
addition to other checks for correct safety belt system function. A new belt and retractor assembly
must be installed if the safety belt assembly's ALR feature or any other safety belt function is not
operating correctly when inspected according to the functional inspection procedures. Failure to
install a new belt and retractor assembly could increase the risk of injury in collisions.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7829
Explorer/Mountaineer and Explorer Sport Trac with 60/40 bench seat
1. Remove the appropriate 60 percent or 40 percent bench seat.
Explorer Sport Trac
2. Remove the rear trim panels.
Explorer/Mountaineer with 60/40 E-Z entry seat
3. Tilt the headrest to the E-Z entry position. 4. Fold the appropriate seat and tilt FORWARD to the
E-Z entry position.
Explorer/Mountaineer with 60/40 E-Z entry and bench seat
5. Remove the upper C-trim pillar panel. 6. Position the rear quarter trim panel aside to access the
safety belt retractor.
All vehicles
7. Remove the bolt and safety belt retractor anchor.
- To install, tighten to 40 Nm (30 lb-ft).
8. Remove the bolt and D-ring.
- To install, tighten to 40 Nm (30 lb-ft).
9. Remove the bolt and safety belt retractor.
- To install, tighten to 40 Nm (30 lb-ft).
10. To install, reverse the removal procedure. 11. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7830
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Third Row
SAFETY BELT RETRACTOR - THIRD ROW
Removal and Installation
WARNING: All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped,
buckles, shoulder belt height adjusters [if equipped], child safety seat tether attachments and
attaching hardware) should be inspected after any collision. All new belt assemblies should be
installed unless a qualified technician finds the assemblies show no damage and operate correctly.
Belt assemblies not in use during a collision should also be inspected and new assemblies installed
if either damage or incorrect operation is noted.
The automatic locking retractor (ALR) feature of the safety belt retractor must be checked by a
qualified technician to verify that the ALR feature for a child safety seat is functioning correctly, in
addition to other checks for correct safety belt system function. A new belt and retractor assembly
must be installed if the safety belt assembly's ALR feature or any other safety belt function is not
operating correctly when
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor - Front > Page 7831
inspected according to the functional inspection procedures. Failure to install a new belt and
retractor assembly could increase the risk of injury in collisions.
1. Remove the rear quarter trim panel. 2. Remove the bolt and D-ring.
- To install, tighten to 40 Nm (30 lb-ft).
3. Remove the bolt and safety belt retractor anchor.
- To install, tighten to 40 Nm (30 lb-ft).
4. Remove the bolt and safety belt retractor.
- To install, tighten to 40 Nm (30 lb-ft).
5. To install, reverse the removal procedure. 6. Check the active restraint system for correct
operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner
C323
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7836
C303
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7837
C3201
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Driver Safety Belt Retractor Pretensioner > Page 7838
C3202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Attaching Safety Seats With Tether Straps
Seat Belt Tensioner: Description and Operation Attaching Safety Seats With Tether Straps
ATTACHING SAFETY SEATS WITH TETHER STRAPS
Some manufacturers make child safety seats that include a tether strap that goes over the back of
the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as
an accessory. Contact the manufacturer of the child safety seat for information about ordering a
tether strap.
Refer to Child Safety Seat Tether Anchor - Second Row and Child Safety Seat Tether Anchor Third Row in the removal and installation portion or the owner's literature for usage information.
See: Child Restraint/Child Seat Tether Attachment/Service and Repair/Child Safety Seat Tether
Anchor - Second Row See: Child Restraint/Child Seat Tether Attachment/Service and Repair/Child
Safety Seat Tether Anchor - Third Row
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Attaching Safety Seats With Tether Straps > Page 7841
Seat Belt Tensioner: Description and Operation Safety Belt Buckle Pretensioners
SAFETY BELT BUCKLE PRETENSIONERS
As part of the SRS, the safety belt buckles are equipped with pretensioners. The safety belt buckle
pretensioners remove excess slack from the safety belt webbing. The pretensioners are activated
by the RCM when the module detects a crash event force exceeding a programmed limit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Page 7842
Seat Belt Tensioner: Service and Repair
SAFETY BELT BUCKLE AND PRETENSIONER
Removal and Installation
WARNING:
- All safety belt assemblies (including retractors, belt tension sensors [BTS] if equipped, buckles,
shoulder belt height adjusters [if equipped], child safety seat tether attachments and attaching
hardware) should be inspected after any collision. All new belt assemblies should be installed
unless a qualified technician finds the assemblies show no damage and operate correctly. Belt
assemblies not in use during a collision should also be inspected and new assemblies installed if
either damage or incorrect operation is noted. Failure to follow these instructions could increase the
risk of injury in collisions.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- LH shown, RH similar.
All seats
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Description and Operation > Page 7843
NOTE: If equipped with power seats, position the passenger seat track downward to access the
safety belt retractor anchor bolt.
1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and
allows access to all 4 seat-to-floor fasteners. 2. Remove the affected seat and depower the SRS. 3.
Remove the safety belt buckle pretensioner electrical connector cover. 4. Disconnect the safety
belt buckle electrical connectors. 5. Remove the 2 nuts and safety belt buckle pretensioner.
- To install, tighten to 36 Nm (27 lb-ft).
6. To install, reverse the removal procedure. 7. Install the affected seat and repower the SRS. If the
passenger seat has been serviced, do not prove out the SRS at this time.
Passenger seat
8. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS. See: Air Bag Systems/Testing and
Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS)
System Zero Seat Weight Test
All seats
9. Check the active restraint system for correct operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tower Position Sensor > Component
Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Seat Track Position Sensor, Left
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Seat Track Position Sensor, Left > Page 7851
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information >
Locations > Page 7852
C356
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor, Left/Right
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor, Left/Right > Page 7858
View 151-18 (Left Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor, Left/Right > Page 7859
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor, Left/Right > Page 7860
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Forward Crash Sensor, Left/Right > Page 7861
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor, Left
C1465
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor, Left > Page 7864
C1466
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor, Left > Page 7865
Impact Sensor: Diagrams Side Impact Sensor
C567A
C567B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor, Left > Page 7866
C644A
C644B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Forward Crash Sensor, Left > Page 7867
C3248
C3249
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Diagrams > Page 7868
Impact Sensor: Description and Operation
SENSORS
WARNING:
- The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in
which the center tunnel area has been damaged, inspect the mounting and bracket for
deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed.
In addition, make sure the area of the RCM mounting is restored to its original condition.
- Vehicle sensor orientation is critical for correct restraint system operation. If a vehicle equipped
with an SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Replace and correctly position the sensor or any other damaged SRS components
whether or not the air bag is deployed.
For these vehicles, the SRS uses up to 6 satellite sensors in addition to the RCM. The RCM is
mounted to the center tunnel beneath the console. All vehicles will have 2 front impact severity
sensors located in the front-center area of the vehicle, behind the grille mounted on the lower
radiator support. The first row impact sensors are located in each of the front doors behind the trim
panel. If the vehicle is equipped with safety canopies, there are 2 additional side impact sensors.
The 2 additional sensors are located on each C-pillar. Mounting orientation and torque is critical for
correct operation of all impact and rollover sensors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor
Impact Sensor: Service and Repair Front Impact Severity Sensor
FRONT IMPACT SEVERITY SENSOR
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. Install and properly position the sensor or any other
damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
- To reduce the risk of 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.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 7871
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Remove the 4 pin-type retainers and the lower radiator air deflector.
3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is
critical for correct system operation.
NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free
of foreign material.
- Note position of locator tab on sensor bracket for installation.
Remove the front impact severity sensor bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Disconnect the front impact severity sensor electrical connector and remove the sensor. 5. To
install, reverse the removal procedure. 6. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 7872
Impact Sensor: Service and Repair Side Impact Sensor
C-Pillar
SIDE IMPACT SENSOR - C-PILLAR
Removal and 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Install a new sensor and correctly position the sensor or any other damaged SRS
components whether or not the air bag is deployed.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- RH side shown, LH similar.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 7873
- The RH and LH C-pillar mounted side impact sensors are not interchangeable.
1. Depower the system. 2. Remove the rear door scuff plate. 3. Detach the rear door weatherstrip.
4. Remove the 2 lower C-pillar trim panel retaining clips from the rear door opening sheet metal.
5. Position aside the lower C-pillar trim panel.
- Pull out on the quarter trim panel at the C-pillar to release the 3 retaining clips and access the
C-pillar side impact sensor.
6. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for
correct system operation.
NOTE: -
Note the position of the sensor and bracket locating tab for installation.
- Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign
material.
Remove the 2 bolts from the side impact sensor and bracket assembly. To install, tighten to 12 Nm (9 lb-ft).
7. Disconnect the electrical connector and remove the side impact sensor. 8. To install, reverse the
removal procedure. 9. Repower the system.
Front Door
SIDE IMPACT SENSOR - FRONT DOOR
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 7874
Removal and 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.
- Vehicle sensor orientation is critical for correct system operation. If a vehicle equipped with an air
bag SRS is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for
deformation. Install a new sensor and correctly position the sensor or any other damaged SRS
components whether or not the air bag is deployed.
- 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 SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Driver side shown, passenger side similar.
1. Depower the system. 2. Remove the front interior door trim panel. 3. Detach the rearward lower
corner of the watershield on the door to expose the side impact sensor. 4. Disconnect the side
impact sensor electrical connector.
5. WARNING: The tightening torque of the side impact sensor retaining bolt is critical for correct
system operation.
CAUTION: The ground wire must be placed between the bolt head and the sensor. Never position
the ground wire between the U-nut
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front Impact Severity Sensor > Page 7875
and the sensor.
NOTE: Make sure the side impact sensor mating surfaces are clean and free of foreign material.
- Note the position of the side impact sensor locating tabs for installation.
Remove the bolt and the side impact sensor. To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure. 7. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 7880
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver
C3065
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 7883
C3066
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Diagrams > Page 7884
Seat Belt Buckle Switch: Description and Operation
SAFETY BELT BUCKLE SWITCHES
As part of the SRS, the front safety belt buckles are equipped with safety belt buckle switches. The
safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The
safety belt buckle switches (Hall-effect sensors) are located in the driver and front passenger safety
belt buckles. The safety belt buckle switches indicate to the RCM whether the safety belts are
buckled or unbuckled. The RCM uses this information in determining the deployment rate of the
dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety
belt buckle switch status to the instrument cluster module, which monitors the information to control
the safety belt warning indicator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tower Position
Sensor > Component Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Locations
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Occupant Classification Sensor Module
C3159
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Occupant Classification Sensor Module > Page 7893
C3291
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Diagrams > Occupant Classification Sensor Module > Page 7894
C3292
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > OCS System
Seat Occupant Sensor: Description and Operation OCS System
OCS System
The OCS system is found only on the front passenger seat. The front passenger OCS system is
comprised of the following: 2 OCS rails (weight sensors) that are mounted to each side of the seat
track; an OCS module (electronic control unit) which is mounted to the electrical bracket
underneath the seat cushion pan. The weight of any occupant or object on the front passenger seat
is electronically communicated to the OCS module.
The OCS system is also used for operation of the passenger Belt Minder. To deactivate or
reactivate the passenger Belt Minder feature, refer to Seat Belt Systems or the owner's literature.
The components that make up the OCS system, OCS module, inboard OCS rail and outboard OCS
rail are serviced separately.
When the front passenger seat is removed for service, the Zero Seat Weight Test must be carried
out after the installation of the front passenger seat. When a OCS system component is installed
new, the System Reset must be carried out after the installation of the front passenger seat. The
Zero Seat Weight Test and/or System Reset must be carried out only as instructed to do so.
OCS Rails (Weight Sensors)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > OCS System > Page 7897
The components that make up the OCS system (OCS system module, inboard OCS rail and
outboard OCS rail) are serviced separately.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > OCS System > Page 7898
Seat Occupant Sensor: Description and Operation Occupant Classification Sensor (OCS) System
OCCUPANT CLASSIFICATION SENSOR (OCS) SYSTEM
The occupant classification system (OCS) system is standard equipment on all front passenger
seats.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 7899
Seat Occupant Sensor: Service and Repair
OCCUPANT CLASSIFICATION SENSOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 7900
Part 2
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.
- The occupant classification sensor rails have a built-in strain gauge which may operate incorrectly
if an occupant classification sensor rail is dropped by itself, dropped when installed to the front
passenger seat or dropped when installed to a front passenger seat track assembly. Use care
when handling an occupant classification sensor rail or when installed to the front passenger seat
of front passenger seat track assembly. Failure to follow these instructions may increase the risk of
personal injury or death in a crash.
- Do not disassemble the occupant classification sensor rail, tighten or loosen any of the nuts and
bolts installed to the occupant classification sensor rail body. Only the 8 bolts that attach the 2
occupant classification sensor rails to the seat track should be removed and installed. Failure to
follow these instructions may increase the risk of personal injury or death in a crash.
- Oil, grease, water or foreign material on or in the occupant classification sensor rail may cause
the supplemental restraint system to deploy incorrectly. Never allow oil, grease, water or foreign
material to get on or into the occupant classification sensor rail. Failure to follow these instructions
may increase the risk of personal injury or death in a crash.
- To reduce the risk of personal injury, do not use any memory saver devices.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- 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.
- Outboard occupant classification sensor (OCS) rail shown, inboard similar.
1. Remove the passenger seat and depower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 7901
2. CAUTION: Push only on the tip of the occupant classification sensor (OCS) electrical connector
release tab to release the electrical
connector. Do not insert the tool too deep into the OCS electrical connector or damage to the
electrical connector may occur.
NOTE: Note the position and the routing of the OCS rail electrical wiring, connector and wiring
retainers for installation.
On the affected side, detach the 2 OCS rail wiring retainers. Then using a suitable tool, release the
tab and disconnect the OCS rail electrical connector.
3. If equipped, disconnect the power seat track motor electrical connector.
4. Move the seat to the forward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Remove the 2 rear bolts from the affected OCS rail.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 7902
6. Move the seat to the rearward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
7. NOTE: Note the position of where the locator tab on the OCS rail goes through the OCS rail
shield and into the rear mounting point of the seat
track for installation.
Remove the 2 front bolts and the affected OCS rail and shield.
Installation
NOTE: If installing a new seat track, position the seat track where the seat will be in the rearward
most position before starting installation of the OCS rails.
1. WARNING: The occupant classification sensor rail shield is an aid to prevent foreign material
and contaminants from entering the
occupant classification sensor rail. Make sure the occupant classification sensor rail shield is
present, is not damaged and is correctly installed to the occupant classification sensor rail. Failure
to follow these instructions may increase the risk of personal injury or death in a crash.
NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Align the locator tab to
the shield.
Position the OCS rail shield on the OCS rail. Then position the OCS rail and shield on the seat
track while noting the correct installation of the OCS rail locator tab into the seat track.
2. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence
shown.
While holding the OCS rail and shield firmly in position, install the OCS rail front mounting position
rear bolt. Tighten to 25 Nm (18 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Component Information > Description and Operation > Page 7903
3. While still holding the OCS rail and shield firmly in position, install the OCS rail front mounting
position front bolt.
- Tighten to 25 Nm (18 lb-ft).
4. Move the seat to the forward most position.
- If equipped with a power seat track, apply power and ground to the pins shown.
5. Install the 2 rear OCS rail bolts.
- Tighten to 25 Nm (18 lb-ft).
6. NOTE: Make sure to route the OCS rail wiring and install the 2 wiring retainers as noted during
removal.
Connect the OCS rail electrical connector. Then route the OCS rail wiring and attach the 2 wiring
retainers.
7. Center the seat track to the seat cushion pan.
- If equipped with a power seat track, apply power and ground to the pins shown.
8. If equipped, connect the power seat track motor electrical connector. 9. Install the passenger
seat and repower the supplemental restraints system (SRS). Do not prove out the SRS at this time.
10. Carry out the appropriate procedure after installation of an OCS system component.
- If installing the original OCS system component, carry out the Occupant Classification Sensor
(OCS) System Zero Seat Weight Test and prove out the SRS. See: Air Bag Systems/Testing and
Inspection/Component Tests and General Diagnostics/Occupant Classification Sensor (OCS)
System Zero Seat Weight Test
- If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS)
System Reset procedure and prove out the SRS. See: Air Bag Systems/Service and Repair
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Service and Repair
Seat Position Sensor: Service and Repair
SEAT POSITION SENSOR
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
- Power seat track seat position sensor shown, manual seat track position sensor similar.
1. Position the front seat to the rearmost and upward position. 2. Depower the system. 3.
Disconnect the seat position sensor electrical connector.
4. WARNING: The tightening torque of the seat position sensor retaining bolt is critical for correct
system operation.
NOTE: Note the position of the seat position sensor locating tab for installation.
Remove the bolt and the seat position sensor. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Component Information > Service and Repair > Page 7907
6. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Seat Track Position Sensor, Left
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Seat Track Position Sensor, Left > Page 7912
View 151-21 (Passenger Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Page 7913
C356
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 7919
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna >
Component Information > Service and Repair
Global Positioning System Antenna: Service and Repair
GLOBAL POSITIONING SYSTEM (GPS) ANTENNA
Removal and Installation
1. Remove the audio unit. 2. Remove the passenger air bag module. 3. Remove the GPS antenna
screw. 4. Release the antenna cable locators and remove the GPS antenna. 5. To install, reverse
the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Cable - Satellite Radio
Antenna Cable: Service and Repair Antenna Cable - Satellite Radio
ANTENNA CABLE - SATELLITE RADIO
Removal and Installation
1. Remove the RH A-pillar trim panel. 2. Disconnect the satellite antenna electrical connector.
- Separate the satellite radio antenna cable pin-type retainers from the A-pillar and instrument
panel.
3. Lower the glove compartment.
- Open the glove compartment door.
- Press the tabs inward and lower the glove compartment.
4. Disconnect the satellite radio antenna cable from the satellite radio receiver. 5. To install,
reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Antenna Cable - Satellite Radio > Page 7929
Antenna Cable: Service and Repair Antenna Lead-In Cable
ANTENNA LEAD-IN CABLE
Removal and Installation
1. Remove the audio unit. 2. Lower the glove compartment door.
3. NOTE: Release the pin-type retainers.
Disconnect the antenna lead-in cable connection and remove the antenna lead-in cable.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter
> Component Information > Service and Repair
Alarm System Transmitter: Service and Repair
PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER
Removal and Installation
1. Remove the steering column cover. 2. Remove the ignition lock cylinder. 3. Remove the 3
screws and the lower steering column shroud. 4. Remove the PATS transceiver.
1 Release the 2 tabs.
2 Disconnect the electrical connector.
5. NOTE: Replacement of the PATS transceiver does not require the PATS keys to be
programmed into the instrument cluster again.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter
> Component Information > Service and Repair > Page 7934
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Diagrams
C2007
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 7942
C500
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 7943
Keyless Entry Key-Pad: Testing and Inspection
KEYLESS ENTRY KEYPAD CODE PROGRAMMING
NOTE: A maximum of 3 personal entry codes can be programmed into the vehicle. The personal
entry codes can be associated with up to two memory seat/adjustable pedal settings.
1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds
to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation
erases all
the stored customer codes. The existing codes do not need to be erased to program a new code.
3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. 4. Press the 1/2, 3/4, or 5/6
to indicate which of the three personal entry code positions is to be programmed. 5. The door locks
lock and unlock to confirm the new code is programmed. 6. To program an additional personal
entry code, REPEAT steps 2 through 4.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Locations > Page 7944
Keyless Entry Key-Pad: Service and Repair
KEYLESS ENTRY KEYPAD
Removal and Installation
1. Position the front window glass to the full down position. 2. Position the door glass top run aside
to access the door pillar trim panel screws. 3. Remove the 3 door pillar trim panel screws and the
door pillar trim panel. 4. Disconnect the electrical connector and remove the keyless entry keypad
from the door pillar trim panel. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming
Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming
REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING
NOTE:
- All remote keyless entry (RKE) transmitters must be programmed at the same time.
- Programming of the RKE transmitters can be accomplished using a scan tool or by carrying out
the following steps:
1. The vehicle must be electronically unlocked before entering program mode using the RKE
transmitter, keyless entry keypad (if equipped) or door
lock control switch while the driver door is open.
2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If
the module successfully enters the program
mode, it locks and then unlocks all doors.
3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock
to confirm that each RKE transmitter is
programmed. Repeat this step for each RKE transmitter.
4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the
button again. If the door locks still fail to respond,
refer to Inspection and Verification. Make sure that no more than the maximum number of 6 RKE
transmitters are attempted to be programmed. See: Body and Frame/Locks/Power Locks/Testing
and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification
5. Exiting the programming mode is accomplished if one of the following occurs:
- The key transitions to the OFF position.
Twenty seconds have passed since entering programming mode or since the last RKE transmitter
was programmed.
- The maximum number of 6 RKE transmitters have been programmed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry Transmitter Programming >
Page 7949
Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming
AUTOLOCK AND HORN CHIRP PROGRAMMING
Autolock Programming Using the Keyless Entry Keypad
1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit
permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code,
press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and
while holding the 3/4 button, press the 7/8 button on the keyless entry keypad and release it.
6. NOTE: If the autolock is disabled, the horn chirps once. If the autolock feature is enabled, the
horn chirps once shortly and then sounds a second
time with a longer sound of the horn once the above sequence is completed.
Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad.
Autolock Programming Using the Ignition Lock Cylinder
1. Close all doors and windows. 2. Confirm that the ignition key is OFF.
3. NOTE: Steps 5 through 9 must be carried out within 30 seconds.
Turn the ignition key from OFF to RUN.
4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to
OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from
OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to
accept program changes. 9. Press the door lock control switch UNLOCK button then the LOCK
button 1 time to command the module to toggle the autolock/relock feature.
10. Verify that the horn chirps. There should be 1 chirp indicating that autolock/relock feature has
been disabled. If 1 chirp is heard, followed by a
longer sound of the horn, the autolock/relock feature has just been enabled.
11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify
that the horn chirps once to indicate that a feature has been changed and that autolock/relock has
been toggled.
Auto-Unlock Programming Using the Keyless Entry Keypad
1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit
permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code,
press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and
while holding the 3/4 button, press the 7/8 button twice on the keyless entry keypad and release it.
6. NOTE: If the auto-unlock is disabled, the horn chirps once. If the auto-unlock feature is enabled,
the horn chirps twice.
Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad.
Auto-Unlock Programming Using the Ignition Lock Cylinder
1. Close all doors and windows. 2. Confirm that the ignition key is OFF.
3. NOTE: Steps 5 through 9 must be carried out within 30 seconds.
Turn the ignition key from OFF to RUN.
4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to
OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from
OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to
accept program changes. 9. Press the door lock control switch LOCK button then the UNLOCK
button 1 time to command the module to toggle the auto-unlock feature.
10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been
disabled. If 1 chirp is heard, followed by a longer
sound of the horn, the auto-unlock feature has just been enabled.
11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify
that the horn chirps once to indicate that a feature has been changed and that auto-unlock has
been toggled.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Service and Repair > Procedures
Keyless Entry Transmitter: Procedures
Remote Memory Activation
REMOTE MEMORY ACTIVATION
1. Position the driver seat and adjustable pedals to the desired position. 2. Press the set button on
the lower center of the instrument panel. 3. Within 5 seconds press one control on the remote
keyless entry (RKE) transmitter and then the 1 or 2 button on the lower center of the instrument
panel to associate the RKE transmitter to the driver 1 or the driver 2 position. This stores the
configuration for driver 1 or driver 2.
4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter.
Remote Memory Deactivation
REMOTE MEMORY DEACTIVATION
1. Press the set button on the lower center of the instrument panel. 2. Within 5 seconds press one
control on the remote keyless entry (RKE) transmitter and then the set button on the lower center
of the instrument
panel to associate the RKE transmitter to the driver 1 or the driver 2 position.
3. If a second memory setting is desired to be deactivated, repeat the procedure with the second
RKE transmitter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Service and Repair > Procedures > Page 7952
Keyless Entry Transmitter: Removal and Replacement
TAILGATE LATCH REMOTE CONTROL
Removal and Installation
1. Open and support the tailgate. 2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate
access panel.
- To install, tighten to 5 Nm (44 lb-in).
3. Open the 2 clips and release the 2 tailgate latch actuating rods from the tailgate remote control.
4. Release the 2 tailgate latch actuating rod locators from the tailgate. 5. Remove the 2 nuts and
the tailgate remote control.
- To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 7957
C3267
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 7958
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 7959
Explorer Sport Trac
Removal and Installation
Mountaineer
1. Remove the passenger rear quarter trim panel.
Explorer Sport Trac
2. Remove the cab rear trim panel.
All vehicles
3. Remove the bolt and the parking aid module.
- Disconnect the electrical connectors.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Locations
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left
C4009
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7965
C4011
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7966
C4010
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 7967
C4012
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Diagrams > Page 7968
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
Removal and Installation
1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor(s) electrical connector(s).
3. Press the retaining tabs and remove the parking aid sensor(s). 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Diagrams
C3268
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 7975
C253
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Locations > Page 7976
Driver/Vehicle Information Display: Description and Operation
INFORMATION AND MESSAGE CENTER
The message center is a liquid crystal display (LCD), integrated into the instrument cluster. The
message center functions are controlled by the TRIP/RESET button on base instrument clusters,
and by the message center switches on high series instrument clusters. The base series
instrument cluster message center has a display format of 2 lines x 12 characters, and the high
series instrument cluster message center has a display format of 4 lines x 12 characters. The
message center displays important vehicle information by constantly monitoring different vehicle
systems. The message center notifies the driver of a potential vehicle problem by displaying a
warning message pertaining to the system in which a fault has been detected. Refer to the Owner's
Literature for operating instructions.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step.
4. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM.
If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle.
- Check the scan tool connection to the VCM.
- Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to
diagnose no communication with the scan tool.
6. If the scan tool does not communicate with the vehicle:
- Verify the ignition key is in the ON position.
- Verify the scan tool operation with a known good vehicle.
- Refer to Information Bus (Module Communications Network) to diagnose no response from the
powertrain control module (PCM).
7. Carry out the network test:
- If the scan tool responds with no communication for one or more modules, refer to Information
Bus (Module Communications Network).
- If the network test passes, retrieve and record the continuous memory DTCs.
8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster. 9. If
the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble
Code (DTC) Chart. For all other DTCs, refer to
Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code
Descriptions
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Principles of Operation
PRINCIPLES OF OPERATION
The message center electronic functions use both hardwired inputs and the controller area network
(CAN) to transmit and receive information. It is very important to understand:
- where the input (command) originates.
- all the information (messages) necessary in order for a feature to operate.
- which module(s) receive(s) the input or command message.
- if the module which received the input (message) controls the output of the feature, or if it outputs
a message over the CAN circuit to another module.
- which module controls the output of the feature.
The message center provides the following features:
- Information displays
- Setup displays
- System check messages
- Warning messages
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The message center information can be selected through the TRIP/RESET button (base cluster)
and by the INFO, SETUP, and RESET buttons (high series cluster).
Information Displays (Base Instrument Cluster)
The information displays are non-timed modes. The selected mode remains on until the driver
presses a message center switch to change the mode, or until it is overridden by another mode.
The information display modes are: Odometer/trip odometer, compass headings
- Distance to empty
- Average fuel economy
- Setup menu
Information Displays (High Series Instrument Cluster)
The information displays are non-timed modes. The selected mode remains on until the driver
presses a message center switch to change the mode, or until it is overridden by another mode.
The information display modes are: Odometer/trip odometer, compass headings, outside air temperature display (with dual electronic
automatic temperature control)
- Distance to empty
- Average fuel economy
- Instantaneous fuel economy
- Fuel used
- Trip elapsed drive time
- Blank
Setup Displays (Base Instrument Cluster)
The setup displays are timed modes and terminate after a finite interval. Press the TRIP/RESET
button to scroll through the SETUP MENU display sequence. If the TRIP/RESET button is not
pressed within 4 seconds, the message center returns to the INFO MENU. The setup display
modes are: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only)
- System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Parking aid
- Oil life start value
Setup Displays (High Series Instrument Cluster)
The setup displays are timed modes and terminate after a finite interval. Press the SETUP button
for the following displays: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only)
- System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Running boards (if equipped)
- Easy entry/exit seat
- Parking aid
- Compass zone
- Compass calibration
- Oil life start value
System Check Displays
Selecting this function from the SETUP MENU causes the message center to cycle through each of
the systems being monitored. For each of the monitored systems, the message center indicates
either an OK message or a warning message for 2 seconds. For base instrument clusters, the
TRIP/RESET button must be held down after pressing the TRIP/RESET button to cycle the
messages through each of the systems being monitored. For high series instrument clusters,
pressing the RESET control switch cycles the message center through each of the systems being
monitored. The system check report is as follows: OIL LIFE RESET
- CHARGING SYSTEM
- WASHER FLUID
- DOOR AJAR
- EXTERIOR LAMPS
- BRAKE FLUID LEVEL
- PARK BRAKE
- FUEL LEVEL
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7980
System Warnings
The system warnings alert the operator to possible problems or malfunctions in the vehicle
operating systems. The message center displays the last selected feature if there are no more
warning messages. This allows the operator full functionality of the message center after
acknowledgement of the warning message by pressing the RESET button and clearing the
message. The warning messages are divided into 4 categories: They cannot be cleared until the condition is corrected.
- They reappear on the display 10 minutes from the reset if the condition has not been corrected.
- They do not reappear until an ignition OFF-ON cycle has been completed.
- They reappear if the condition clears then reoccurs within the same ignition ON-OFF cycle.
The warning displays that cannot be reset are: DOOR AJAR
- CLEAR OBJECTS BY PASS SEAT
The warning messages that reoccur after 10 minutes are: CHECK CHARGING SYSTEM
- FUEL LEVEL LOW
- PARK BRAKE ENGAGED
- CHECK BRAKE SYSTEM
The warning messages that display whenever the ignition switch is turned from the OFF position to
the ON position are: CHECK PARK AID
- BRAKE FLUID LEVEL LOW
- CHECK HEADLAMP
- CHECK HIGHBEAM
- CHECK TURN LAMP
- WASHER FLUID LOW LEVEL
- OIL CHANGE REQUIRED
- ENGINE OIL CHANGE SOON
The warning messages that return after a condition has cleared then reoccurs within the same
ignition ON-OFF cycle are: LIFTGATE/GLASS AJAR
- LOW TIRE PRESSURE
- TIRE MONITOR FAULT
- TIRE SENSOR FAULT
- TRAIN TIRES
- TIRES TRAINED
- TIRES NOT TRAINED
Outside Air Temperature Sensor (Base Instrument Cluster without Electronic Automatic
Temperature Control [EATC])
The base instrument cluster receives the outside air temperature data from the outside air
temperature sensor. This data is then displayed on the message center. The outside air
temperature sensor is located on the radiator core support behind the front grill assembly and is
fastened with a pin-type retainer. If equipped with a high series instrument cluster, the outside air
temperature data from the outside air temperature sensor is displayed in the electronic automatic
temperature control (EATC) module.
Compass
The compass heading is displayed as one of N, NE, E, SE, S, SW, W and NW in the message
center display. The compass reading may be affected when you drive near large buildings, bridges,
power lines and powerful broadcast antenna. Magnetic or metallic objects placed in, on or near the
vehicle may also affect compass accuracy. The compass sensor module is mounted behind the
interior rear view mirror.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7981
B1255-B2097 / U2013
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7982
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7983
Symptom Chart (Part 2)
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7984
Symptom Chart (Part 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7985
Symptom Chart (Part 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7986
Symptom Chart (Part 5)
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7987
Driver/Vehicle Information Display: Pinpoint Tests
Test A: The Message Center Is Not Operating Correctly
PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH
SERIES INSTRUMENT CLUSTER)
A1
A2
Normal Operation
The message center functionality is controlled through the message center switch, which is
hardwired to the instrument cluster through circuits CMC29 (GN/VT) and RMC32 (GN/BU).
Possible Causes
- Message center switch
- Instrument cluster
Test B: The Compass Is Inoperative
PINPOINT TEST B: THE COMPASS IS INOPERATIVE.
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7988
B1
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7989
B2-B3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7990
B4
Normal Operation
The compass sensor module receives voltage from the smart junction box (SJB) through circuit
CBP18 (GY/OG) and is grounded through circuit GD143 (BK/VT). The compass sensor module
communicates the vehicle direction to the instrument cluster, which is displayed in the message
center. The compass sensor module uses circuits VMC30 (BU/GY) and VMC31 (YE/GN) to
communicate to the instrument cluster.
DTC B2097 - is a continuous memory DTC that sets in the instrument cluster if the data received
from the compass module is invalid.
DTC U2013 - is a continuous and on-demand DTC that sets if the instrument cluster fails to receive
a response from the compass module after 4 consecutive attempts.
Possible Causes
- Fuse
- Circuit CBP18 (GY/OG) open
- Circuit GD143 (BK/VT) open
- Circuit VMC30 (BU/GY) open or short to ground
- Circuit VMC31 (YE/GN) open or short to ground
-- Compass sensor module
Test C: The Compass Is Inaccurate
PINPOINT TEST C: THE COMPASS IS INACCURATE
C1-C2
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C2
Normal Operation
The compass sensor module communicates the vehicle direction to the instrument cluster to
display in the message center.
Possible Causes
- Compass out of calibration
- Zone setting
- Vehicle is magnetized
- Compass sensor module
Test D: The Message Center Switch Does Not Operate Correctly
PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
(HIGH SERIES INSTRUMENT CLUSTER)
D1-D2
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D2-D4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7993
D4-D5
Normal Operation
The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch
function to the instrument cluster message center. The message center switch is grounded through
circuit RMC32 (GN/BU). Each message center switch uses a different resistance value allowing the
instrument cluster to determine which switch is pressed.
Possible Causes
- Circuit CMC29 (GN/VT) open, short to ground or voltage
- Circuit RMC32 (GN/BU) open
- Message center switch
- Instrument cluster
Test E: The Outside Air Temperature Display Does Not Operate Correctly
PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE
CORRECTLY
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7994
E1-E3
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E3-E5
NOTE: The outside air temperature display is only available in base instrument clusters without
electronic automatic temperature control (EATC).
Normal Operation
The outside air temperature sensor is hardwired to the instrument cluster through circuits VH407
(YE/GN) and RMC32 (GN/BU). The message center displays the outside air temperature upon
receipt of the outside air temperature data.
DTC B1255 - is a continuous and on-demand DTC that sets if the instrument cluster detects an
open on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster
detects an open on the outside air temperature input, the instrument cluster defaults the display to
23.5° Celsius (75°F).
DTC B1257 - is a continuous and on-demand DTC that sets if the instrument cluster detects a short
to ground on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument
cluster detects a short to ground on the outside air temperature input, the instrument cluster
defaults
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the display to 23.5°Celsius (75°F).
Possible Causes
- Circuit VH407 (YE/GN) open or short to ground
- Circuit RMC32 (GN/BU) open
- Ambient air temperature sensor
- Instrument cluster
Test F: The Washer Fluid Low Level Warning Is Inoperative
PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE
F1-F2
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F3-F6
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7998
F6-F7
Normal Operation
The instrument cluster is hardwired to the low washer fluid switch (part of the windshield washer
reservoir) through circuit CMC20 (VT). The low washer fluid switch closes when the washer fluid
level is approximately 1/3 full, providing a ground to the instrument cluster through circuit GD108
(BK/VT) and turning on the WASHER FLUID LOW LEVEL warning. When the washer fluid is above
the low level, the low washer fluid switch opens, removing the ground to the instrument cluster, and
the WASHER FLUID LOW LEVEL warning turns off.
Possible Causes
- Circuit GD108 (BK/VT) open
- Circuit CMC20 (VT) open or short to ground
- Washer fluid level switch (part of the windshield washer reservoir)
- Instrument cluster
Test G: The Check Charging System Warning Is Inoperative
PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE
G1-G2
Normal Operation
The charging system warning indicator is controlled by the instrument cluster based upon data
received from the powertrain control module (PCM)
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over the high speed controller area network (HS-CAN).
Possible Causes
- Charging system
- Instrument cluster
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Procedures
Driver/Vehicle Information Display: Procedures
Message Center Cluster
OIL LIFE RESET - MESSAGE CENTER CLUSTER
NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days.
1. Press and release the SETUP button until the message center displays PRESS RESET TO
BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center
displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and
release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET.
Base Instrument Cluster
OIL LIFE RESET - BASE INSTRUMENT CLUSTER
NOTE: Oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days.
1. Press and release the TRIP/RESET button until the message center displays SETUP MENU
HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center
displays RESET FOR SYSTEM CHECK. 3. Press and hold the TRIP/RESET button for 2 seconds
until the message center displays OIL LIFE xx% RESET IF NEW. 4. Press and release the
TRIP/RESET button until the message center displays HOLD RESET IF NEW OIL. 5. Press and
hold the TRIP/RESET button for 2 seconds and release to reset the oil life to 100%. 6. Message
center briefly displays OIL CHANGE SET TO 100%.
Message Center Cluster
OIL LIFE START VALUE - MESSAGE CENTER CLUSTER
NOTE: The oil life start value is used to reset the oil life value back to the maximum of
approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value
from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%.
1. Press and release the SETUP button until the message center displays OIL LIFE START
VALUE SET TO XX%. 2. Press and release the RESET button to lower the percentage by 10%
(down to 10%) for each button press or return the value to 100%.
Base Instrument Cluster
OIL LIFE START VALUE - BASE INSTRUMENT CLUSTER
NOTE: The oil life start value is used to reset the oil life value back to the maximum of
approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value
from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%.
1. Press and release the TRIP/RESET button until the message center displays SETUP MENU
HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center
displays RESET FOR SYSTEM CHECK. 3. Press and release the TRIP/RESET button until the
message center displays OIL LIFE SET TO XX%. 4. Press and hold the TRIP/RESET button for 2
seconds to lower the percentage by 10% (down to 10%) for each button press-and-hold or return
the
value to 100%.
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Procedures > Page 8002
Driver/Vehicle Information Display: Removal and Replacement
MESSAGE CENTER SWITCH
Removal and Installation
1. Remove the instrument panel center finish panel.
2. Press the retaining tabs and remove the message center switch. 3. To install, reverse the
removal procedure.
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Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack,
Entertainment System > Component Information > Diagrams
C3312
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack,
Entertainment System > Component Information > Diagrams > Page 8008
Auxiliary Input / Output Jack: Service and Repair
AUDIO INPUT JACK
Removal and Installation
1. Remove the floor console finish panel.
2. Release the tabs and remove the audio input jack. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Diagrams
C949
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Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component
Information > Diagrams > Page 8012
DVD Player: Service and Repair
DIGITAL VERSATILE DISC (DVD) PLAYER
Removal
NOTE: Programmable module installation (PMI) only needs to be carried out if the DVD player is
being replaced.
1. Upload the DVD player configuration to the scan tool.
2. NOTE: Open the DVD player display.
Remove the 4 screws.
3. Remove the DVD player.
- Pull down on the sides of the DVD player to disengage the clips from the bracket.
- Using a suitable tool, push the rear most U-hook forward and release the U-hooks.
- Hang the DVD player on the J-hooks and disconnect the electrical connector.
- Remove the DVD player from the J-hooks.
Installation
1. Hang the DVD player on the J-hooks. 2. Connect the electrical connector. 3. Remove the DVD
player from the J-hooks.
4. NOTE: Tilt the DVD player, as necessary, to align it correctly.
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Align the left side guide pin with the left side locating hole.
5. Lift up the right side of the DVD player and engage the U-hooks. 6. Install the 4 screws. 7. Push
on the left and right sides of the DVD player to engage the clips. 8. Download the DVD player
configuration from the scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Description and Operation
Garage Door Opener Transmitter: Description and Operation
UNIVERSAL TRANSMITTER
The universal transmitter, located in the overhead console, provides a convenient way to substitute
up to 3 hand-held transmitters with a single built-in device. The universal transmitter can learn the
radio frequency codes of most current transmitters.
The universal transmitter:
- operates garage doors, gates and home/office lighting and security systems.
- learns and transmits the radio frequency of up to 3 hand-held transmitters from any of the
systems mentioned above.
- is powered by the vehicle battery and charging system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Visually inspect the following for obvious signs of electrical
damage.
VISUAL INSPECTION CHART
Electrical Universal transmitter
- Receiver unit
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom. GO to
Symptom Chart. See: Symptom Related Diagnostic Procedures
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8019
Symptom Chart
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8020
Garage Door Opener Transmitter: Pinpoint Tests
PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE
A1-A5
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A5 Continued
Normal Operation
The universal transmitter is integral to the overhead console. The universal transmitter can be
programmed to operate up to 3 garage doors, entry gates, security systems, and home or office
lighting. Voltage is supplied to the universal transmitter through circuit CLN01 (GN/VT) and
grounded on circuit GD133 (BK).
Possible Causes
- Circuit CLN01 (GN/VT) open
- Circuit GD133 (BK) open
- Receiver unit
- Universal transmitter
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Erasing Channels
Garage Door Opener Transmitter: Service and Repair Erasing Channels
ERASING CHANNELS
1. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures
for programming.
To erase all 3 programmed channels, hold down the 2 outside buttons until the red light begins to
flash (20-30 seconds). Release both buttons.
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Erasing Channels > Page 8024
Garage Door Opener Transmitter: Service and Repair Universal Transmitter Programming
Universal Transmitter Programming
WARNING: A garage door opening system that cannot stop or reverse itself after detecting an
object in its path does not meet current federal safety standards. To decrease the risk of serious
injury or death, do not use this universal transmitter with a door opening system that lacks stop and
reverse features as required by federal standards. This includes any garage door opening system
manufactured before April 1, 1982. Failure to follow these instructions may result in personal injury.
1. Verify the hand-held transmitter is operative. 2. Prepare for programming the universal
transmitter by erasing all 3 channels by holding down the 2 outside buttons until the red light begins
to
flash (20-30 seconds). Release both buttons.
3. Select 1 of the 3 universal transmitter channels to be programmed by pressing the desired
button. 4. Hold the end of the hand-held transmitter 25-51 mm (1-2 in) from the front surface of the
universal transmitter so that the red light can still be
seen.
5. NOTE: During programming, the hand-held transmitter may automatically stop transmitting after
2 seconds, which may not be long enough to
program the universal transmitter. If programming this type of hand-held transmitter, continue to
hold the button on the universal transmitter while pressing the hand-held transmitter button every 2
seconds.
Use both hands to press the hand-held transmitter button and the desired button on the universal
transmitter. Do not release either button.
6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and
then rapidly. Release both buttons when the rapid
flashing begins. The universal transmitter has successfully learned the new frequency signal and
can be used in place of the hand-held transmitter(s).
7. To operate, press the appropriate button on the universal transmitter. The red light is on while
the signal is being transmitted. 8. To program additional hand-held transmitters repeat Steps 3-6.
Training a Garage Door Opener Equipped With "Rolling Codes"
1. Program the hand-held transmitter to the universal transmitter. 2. Train the garage door opener
receiver to recognize the universal transmitter.
1 Remove the cover panel from the garage door opener receiver.
2 Locate the training button on the garage door opener receiver. Location and color of the button
may vary by garage door opener manufacturer. Refer to the garage door opener instruction
manual.
3 Press the training button on the garage door opener receiver for 1-2 seconds.
4 Press the programmed universal transmitter button for as long as the universal transmitter red
light flashes (1-2 seconds). Release the button and press the button to confirm the universal
transmitter is trained to the receiver.
5 The garage door opener should recognize the universal transmitter.
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Service and Repair > Page 8025
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System
Antenna > Component Information > Service and Repair
Global Positioning System Antenna: Service and Repair
GLOBAL POSITIONING SYSTEM (GPS) ANTENNA
Removal and Installation
1. Remove the audio unit. 2. Remove the passenger air bag module. 3. Remove the GPS antenna
screw. 4. Release the antenna cable locators and remove the GPS antenna. 5. To install, reverse
the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning
Module > Component Information > Description and Operation
Memory Positioning Module: Description and Operation
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Belt Tower Position
Sensor > Component Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop
Navigation System: Technical Service Bulletins Audio System - Pioneer Navigation Radio - Seek
Inop
TSB 06-25-3
11/30/06
PIONEER NAVIGATION RADIO - SEEK FUNCTION INOPERATIVE - SERVICE TIP
FORD: 2006-2007 Five Hundred, Freestyle 2007 Fusion, Mustang 2006-2007 Explorer 2007 Edge,
Expedition, Explorer Sport Trac, F-150
LINCOLN: 2006 Zephyr 2007 MKZ, Mark LT, MKX, Navigator
MERCURY: 2006-2007 Montego 2007 Milan 2006-2007 Mountaineer
ISSUE Some 2006-2007 vehicles equipped with a Pioneer Navigation Radio may appear to have a
defective seek function. It may be reported that the radio Seek function is inoperative, Seek will not
stop (keeps scrolling through stations) or the radio exhibits Poor FM reception. This may be due to
a misunderstanding of how the operation of the PTY (Program Type) feature functions. The PTY
feature filters out radio stations that do not fit a selected category of radio programming like: Top
40, Classical, and News. The result is a "continuous seek" condition if the feature is activated and
no stations are found under the selected category.
ACTION Follow the Service Procedure to identify the PTY (Program Type) setting.
SERVICE PROCEDURE
To confirm the PTY (Program Type) setting use the following steps:
1. Under MEDIA, select the FM tab. (If you do not see an RDS and PTY button, push the SHOW
OPTIONS buttons).
2. Verify RDS and PTY are enabled by the buttons being illuminated. If the text, above the SET
PTY button says anything other than ALL, the unit is filtering for radio stations that transmit RDS
text and are categorized as the selected Program Type, like: Top 40, Classical, and News. (See
Figure 1)
3. To change the setting, either press the SET PTY button and select ALL. Or disable the PTY
feature by pushing the PTY button.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 8041
DEALER CODING
CONDITION
BASIC PART NO. CODE
18806 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions
Navigation System: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8044
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8045
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8046
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8047
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8048
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8049
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8050
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8051
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8052
Navigation System: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8053
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8054
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8055
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8056
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8057
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8058
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8059
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8060
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8061
Navigation System: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
130-1
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130-2
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Diagrams > Diagram Information and Instructions > Page 8063
130-3
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Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8064
130-4
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Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8065
130-5
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Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8066
130-6
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Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information >
Diagrams > Diagram Information and Instructions > Page 8067
130-7
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Diagrams > Diagram Information and Instructions > Page 8068
130-8
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Module >
Component Information > Description and Operation
Pedal Positioning Module: Description and Operation
Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver
can adjust the brake and accelerator pedals for a more comfortable driving position. For removal
and installation of the adjustable pedals, refer to Brake Pedal and Bracket.
Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational
with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward
using the adjustable pedal switch.
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations > Page 8076
C2003
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor >
Component Information > Locations > Page 8077
Pedal Positioning Motor: Service and Repair
Brake Pedal Motor
Brake Pedal Motor
Removal and Installation
1. Disconnect the accelerator and brake pedal drive cables from the adjustable pedal motor. 2.
Disconnect the adjustable pedal motor electrical connector. 3. Remove the 2 adjustable pedal
motor screws and then remove the adjustable pedal motor and drive cables as an assembly.
^ To install, tighten to 3 Nm (27 inch lbs.).
4. NOTE: Make sure the brake pedal and the accelerator pedal are in the same position before
connecting the drive cable to the adjustable pedals.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch >
Component Information > Locations > Page 8081
C2089
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Diagrams
C3041
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop
Radio/Stereo: Technical Service Bulletins Audio System - Pioneer Navigation Radio - Seek Inop
TSB 06-25-3
11/30/06
PIONEER NAVIGATION RADIO - SEEK FUNCTION INOPERATIVE - SERVICE TIP
FORD: 2006-2007 Five Hundred, Freestyle 2007 Fusion, Mustang 2006-2007 Explorer 2007 Edge,
Expedition, Explorer Sport Trac, F-150
LINCOLN: 2006 Zephyr 2007 MKZ, Mark LT, MKX, Navigator
MERCURY: 2006-2007 Montego 2007 Milan 2006-2007 Mountaineer
ISSUE Some 2006-2007 vehicles equipped with a Pioneer Navigation Radio may appear to have a
defective seek function. It may be reported that the radio Seek function is inoperative, Seek will not
stop (keeps scrolling through stations) or the radio exhibits Poor FM reception. This may be due to
a misunderstanding of how the operation of the PTY (Program Type) feature functions. The PTY
feature filters out radio stations that do not fit a selected category of radio programming like: Top
40, Classical, and News. The result is a "continuous seek" condition if the feature is activated and
no stations are found under the selected category.
ACTION Follow the Service Procedure to identify the PTY (Program Type) setting.
SERVICE PROCEDURE
To confirm the PTY (Program Type) setting use the following steps:
1. Under MEDIA, select the FM tab. (If you do not see an RDS and PTY button, push the SHOW
OPTIONS buttons).
2. Verify RDS and PTY are enabled by the buttons being illuminated. If the text, above the SET
PTY button says anything other than ALL, the unit is filtering for radio stations that transmit RDS
text and are categorized as the selected Program Type, like: Top 40, Classical, and News. (See
Figure 1)
3. To change the setting, either press the SET PTY button and select ALL. Or disable the PTY
feature by pushing the PTY button.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Technical Service Bulletins > Audio System - Pioneer Navigation Radio - Seek Inop > Page 8090
DEALER CODING
CONDITION
BASIC PART NO. CODE
18806 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Technical Service Bulletins > Page 8091
C3290
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Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Component Information > Technical Service Bulletins > Page 8092
Radio/Stereo: Service and Repair
SATELLITE RADIO RECEIVER
Removal and Installation
1. Remove the RH cowl side trim panel.
2. NOTE: Lower the glove compartment door to access the top nut.
Remove the bolt, the nut, and the satellite radio receiver. Disconnect the satellite radio antenna connector and the electrical connector.
- To install, tighten to 7 Nm (62 lb-in).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Locations
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Locations > Page 8096
C2208
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Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Locations > Page 8097
Remote Control: Service and Repair
STEERING WHEEL CONTROLS
Removal and Installation
1. NOTE:
- It is not necessary to remove the driver air bag module during this procedure.
- When removing the steering wheel controls, disengage the RH side of the controls first.
Using an appropriate tool, pry the steering wheel controls out of the steering wheel.
2. NOTE: Do not allow the electrical connector to fall back into the steering wheel.
Remove the steering wheel controls. Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear
C802
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Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear > Page 8102
C612
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear > Page 8103
C523
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Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Right Rear > Page 8104
C702
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Speaker
Speaker: Service and Repair Door Speaker
DOOR SPEAKER
Removal and Installation
1. Remove the door trim panel. 2. Remove the 4 screws and the door speaker.
- Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Speaker > Page 8107
Speaker: Service and Repair Subwoofer Speaker
SUBWOOFER SPEAKER
Removal and Installation
1. Remove the rear trim panel. 2. Disconnect the electrical connector. 3. Remove the 3 bolts and
the subwoofer enclosure. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8113
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations
View 151-19 (Right Rear)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8117
C3267
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8118
Parking Assist Control Module: Service and Repair
PARKING AID MODULE
Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 8119
Explorer Sport Trac
Removal and Installation
Mountaineer
1. Remove the passenger rear quarter trim panel.
Explorer Sport Trac
2. Remove the cab rear trim panel.
All vehicles
3. Remove the bolt and the parking aid module.
- Disconnect the electrical connectors.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Pedal Positioning Module > Component Information > Description and Operation
Pedal Positioning Module: Description and Operation
Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver
can adjust the brake and accelerator pedals for a more comfortable driving position. For removal
and installation of the adjustable pedals, refer to Brake Pedal and Bracket.
Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational
with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward
using the adjustable pedal switch.
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations
View 151-27 (Rear End)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left
C4009
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left >
Page 8129
C4011
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left >
Page 8130
C4010
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left >
Page 8131
C4012
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8132
Parking Assist Distance Sensor: Service and Repair
PARKING AID SENSOR
Removal and Installation
1. Remove the rear bumper cover. 2. Disconnect the parking aid sensor(s) electrical connector(s).
3. Press the retaining tabs and remove the parking aid sensor(s). 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8136
C2089
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System
Information > Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements
Towing Information: Technical Service Bulletins Vehicle - Tow Capability/Service Kit Requirements
TSB 06-7-1
04/17/06
NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS
FORD: 2004-2006 Focus 2004 F-150 Heritage 2004-2005 Explorer Sport Trac 2004-2006 Escape,
Explorer, F-150-350 Series, Ranger 2005-2006 Escape Hybrid 2007 Explorer Sport Trac
LINCOLN: 2006 Mark LT
MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 06-4-5 to update the vehicle neutral tow application chart.
ISSUE Various vehicles are neutral tow capable. Refer to the following chart to determine neutral
tow capability for specific vehicle applications, and to determine if a Service Kit is required to make
the vehicle neutral tow capable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System
Information > Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements > Page 8142
ACTION Review the neutral tow application chart (Figure 1) and order the kit, if applicable.
Reprogramming of various modules may be required for some installations. Installation instructions
are included with the kit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System
Information > Technical Service Bulletins > Vehicle - Tow Capability/Service Kit Requirements > Page 8143
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module >
Component Information > Locations > Page 8147
C239
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8152
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8153
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8154
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8155
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8156
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8157
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8158
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8159
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8160
Trailer Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8161
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8162
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8163
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8164
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8165
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8166
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8168
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8169
Trailer Connector: Connector Views
C439
C473
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8170
Trailer Connector: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8171
95-2
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 8172
95-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair
Trailer Hitch: Service and Repair
Trailer Hitch
Material
Removal and Installation
NOTE: The factory rear trailer hitch crossmember is welded to the frame. The service replacement
trailer hitch crossmember will be bolted to the frame.
All vehicles
1. Remove the spare tire. 2. Remove the rear bumper cover. 3. Disconnect the trailer wiring
harness.
Explorer/Mountaineer
4. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg.
- Use Explorer/Mountaineer template No. 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8176
EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- For the inboard side use Explorer/Mountaineer template No. 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8177
EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- For the outboard side use Explorer/Mountaineer template No. 3.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8178
EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
Explorer Sport Trac
6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg.
- Use Sport Trac template No. 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8179
SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- Use Sport Trac Template No. 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8180
SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- Use Sport Trac template No. 3.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8181
SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
All vehicles
8. De-burr the cut edges of the frame rail and the drilled holes. 9. Clean the inner and outer
surfaces of the frame rails, making sure all mating surfaces are free of foreign material.
10. Apply 3 even coats of the specified anti-corrosion coating onto the inner and outer surfaces of
the frame rails where bare metal is present.
11. NOTE: It may be necessary to spread apart pull together the frame rails slightly to get brackets
to fit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component
Information > Service and Repair > Page 8182
Insert the new trailer hitch cross member assembly into the frame.
12. Hand start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts.
- Tighten to 235 Nm (174 lb-ft).
14. Tighten the outboard bolts.
- Tighten to 235 Nm (174 lb-ft).
15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Symbols Part 2
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Information > Diagrams > Diagram Information and Instructions > Page 8192
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8193
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8194
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8195
Trailer Lamps: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
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3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
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Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
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Information > Diagrams > Diagram Information and Instructions > Page 8198
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
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Information > Diagrams > Diagram Information and Instructions > Page 8199
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
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8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
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Information > Diagrams > Diagram Information and Instructions > Page 8201
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Diagrams > Diagram Information and Instructions > Page 8203
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
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Information > Diagrams > Diagram Information and Instructions > Page 8204
Trailer Lamps: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
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95-2
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95-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating
correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect the following for obvious
signs of electrical damage.
VISUAL INSPECTION CHART
Electrical Battery junction box (BJB) fuse(s): 13 (30A) (trailer tow battery charge relay - switched)
- 17 (30A) (trailer brake control module)
- Smart junction box (SJB) fuse(s): 7 (15A) (trailer stop/turn lamps)
- 12 (5A) (trailer tow battery charge relay coil)
- 16 (10A) (trailer reversing lamps)
- 25 (15A) (trailer parking lamps and trailer brake control module)
- SJB
- Circuity
- Trailer
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
NOTE:
- Make sure the headlamp switch is in the OFF position.
- Make sure the multifunction switch is in the LOW BEAM position.
5. NOTE: Make sure to use the latest scan tool release software.
If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
6. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM.
If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle.
- Check the scan tool connection to the VCM.
- Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to
diagnose no communication with the scan tool.
7. If the scan tool does not communicate with the vehicle:
- Verify the ignition key is in the ON position.
- Verify the scan tool operation with a known good vehicle.
- Refer to Information Bus (Module Communications Network) to diagnose no response from the
powertrain control module (PCM).
8. Carry out the network test.
- If the scan tool responds with no communication with the SJB, refer to Information Bus (Module
Communications Network).
- If the network test passes, retrieve and record the continuous memory DTCs.
9. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB.
10. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic
Trouble Code (DTC) Chart. For all other DTCs,
refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble
Code Descriptions
11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are
all functioning correctly with the trailer disconnected.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8209
B2070
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8210
Trailer Lamps: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Symptom Chart (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8211
Trailer Lamps: Pinpoint Tests
Test V: The Trailer Lamps Are Inoperative - Trailer Parking Lamps
PINPOINT TEST V: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS
V1-V2
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V2-V3
Normal Operation
Voltage to the trailer parking lamps is supplied by the smart junction box (SJB) through circuit
CAT17 (BN).
Possible Causes
- Fuse
- Circuit CAT17 (BN) open
- Trailer
- SJB
Test W: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps
PINPOINT TEST W: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS
W1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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W1-W3
Normal Operation
Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit
CAT16 (GY/BN).
Possible Causes
- Fuse
- Circuit CAT16 (GY/BN) open
- Trailer
- SJB
Test X: The Individual Trailer Lamp Is Inoperative - LH Trailer Stoplamp
PINPOINT TEST X: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER
STOPLAMP
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8214
X1-X2
X3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8215
Normal Operation
Voltage to the LH trailer stoplamp is supplied by the smart junction box (SJB) through circuit
CAT06 (YE).
DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the LH
trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the
SJB to enable the output for the LH trailer turn/stoplamp voltage supply.
Possible Causes
- Circuit CAT06 (YE) open or short to ground
- Trailer
- SJB
Test Y: The Individual Trailer Lamp Is Inoperative - RH Trailer Stoplamp
PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER
STOPLAMP
Y1-Y2
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
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Y2-Y3
Normal Operation
Voltage to the RH trailer stoplamp is supplied by the smart junction box (SJB) through circuit
CAT09 (GN).
DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the RH
trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the
SJB to enable the output for the RH trailer turn/stoplamp voltage supply.
Possible Causes
- Circuit CAT09 (GN) open or short to ground
- Trailer
- SJB
Test Z: The Trailer Lamps Are On Continuously
PINPOINT TEST Z: THE TRAILER LAMPS ARE ON CONTINUOUSLY
Z1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8217
Z1-Z3
Normal Operation
Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits CAT06 (YE)
and CAT09 (GN) supply voltage to the trailer tow LH and RH stoplamps, respectively.
Possible Causes
- Circuit CAT06 (YE) short to voltage
- Circuit CAT09 (GN) short to voltage
- Trailer
- SJB
Tests AA: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
PINPOINT TEST AA: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8218
AA1-AA3
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8219
AA3-AA4
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8220
AA4-AA5
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AA5 Continued
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AA6-AA8
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AA8-AA10
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AA10-AA11
Normal Operation
The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 12 (5A)
through circuit CBP12 (GN/WH) when the ignition switch is in the RUN or ACC position. Ground for
the trailer battery charge relay coil is supplied through circuit GD120 (BK/GN). The battery junction
box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay through circuit SSB13
(GY/RD). When the trailer battery charge relay is energized, the voltage is routed to the trailer tow
connector through circuit CAT14 (OG).
Possible Causes
- Fuse
- Circuit CAT14 (OG) open or short to voltage
- Circuit CBP12 (GN/WH) open or short to voltage
- Circuit GD120 (BK/GN) open
- Circuit SSB13 (GY/RD) open
- Trailer battery charge relay
- Trailer
- SJB
Tests AB: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
PINPOINT TEST AB: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT
OPERATE CORRECTLY
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AB1-AB2
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Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8226
AB3-AB5
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AB6-AB8
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AB9
Normal Operation
The trailer electric brake controller is provided voltage at all times by the battery junction box (BJB)
fuse 17 (30A) through circuit SBB17 (RD). Ground for the trailer electric brake controller is provided
through circuit GD138 (BK/WH). The trailer electric brake controller receives voltage from the
stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested,
the trailer electric brake controller provides voltage to the trailer tow connector through circuit
CAT19 (BU).
Possible Causes
- Fuse
- Circuit CAT17 (BN) open
- Circuit CAT19 (BU) open, short to ground, or short to voltage
- Circuit CCB08 (VT/WH) open
- Circuit GD138 (BK/WH) open
- Circuit SBB17 (RD) open
- Trailer electric brake controller
- Trailer
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Information > Testing and Inspection > Page 8229
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations > Page 8233
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay >
Component Information > Locations > Page 8237
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8242
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8243
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8244
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8245
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8246
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8247
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8248
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8249
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8250
Trailer Connector: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8251
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8252
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8253
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8254
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8255
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8256
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8257
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8258
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8259
Trailer Connector: Connector Views
C439
C473
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8260
Trailer Connector: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8261
95-2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 8262
95-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Specifications
Torque Specifications
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service and Repair > Driver Seat Module (DSM)
Body Control Module: Service and Repair Driver Seat Module (DSM)
DRIVER SEAT MODULE (DSM)
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service and Repair > Driver Seat Module (DSM) > Page 8270
Removal and Installation
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration
information to a scan tool. This information must be downloaded into the new DSM after
installation.
1. Remove the driver seat. 2. Remove the 2 DSM screws. 3. Disconnect the electrical connectors
and remove the DSM.
4. NOTE: Once the module is installed it is necessary to download the module configuration
information from the scan tool into the new module.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service and Repair > Driver Seat Module (DSM) > Page 8271
Body Control Module: Service and Repair Smart Junction Box (Sjb)
SMART JUNCTION BOX (SJB)
Special Tool(s)
Special Tool(s)
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service and Repair > Driver Seat Module (DSM) > Page 8272
Part 2
Removal
NOTE:
- The steps included in the SJB removal and installation procedure are critical to restoring the
vehicle security and tire pressure monitoring systems to normal operation. A new SJB is delivered
in manufacturing mode with 6 pre-set diagnostic trouble codes (DTCs) related to the tire pressure
monitoring system. The presence of these DTCs requires the installation procedures be followed in
order to clear the DTCs and enable normal SJB operations.
- Prior to the removal of the SJB, it is necessary to upload the module configuration information to
the diagnostic tool. This information must be downloaded to the new SJB after installation.
1. Remove the driver door scuff plate. 2. Position the LH door opening weather seal aside.
3. NOTE: While pulling the trim panel rearward, pull the hood release lever rearward in order for
the release lever to slide through the trim panel.
Remove the pushpin and the cowl side trim panel.
4. Remove the 2 bolts and the parking brake release handle. 5. Disconnect the parking brake
switch electrical connector. 6. Release the hood release cable pushpin from the parking brake
control bracket. 7. Release the harness clip from the parking brake cable housing.
8. NOTE: Rotating the parking brake control counterclockwise allows enough access to clear the
instrument panel reinforcement.
Remove the 3 bolts and position the parking brake control assembly under the brake pedal.
9. CAUTION: The lower side of the headlight switch bezel includes 2 tabs that slide down onto the
instrument panel and may be broken if
any prying force is exerted in the lower area of the bezel.
Using a suitable tool, pry the mid-to-upper side of the headlight switch bezel away from the
instrument panel, disconnect the 2 electrical connectors and position the bezel assembly aside.
10. If necessary, push the LH instrument panel side finish panel out and position it aside. 11.
Through the headlight switch bezel opening, remove the 2 SJB bolts. 12. From under the
instrument panel, remove the third SJB bolt.
13. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service and Repair > Driver Seat Module (DSM) > Page 8273
(connected) position when installing.
Pull the SJB down out of the 2 locating pins, disconnect the 5 electrical connectors and remove the
SJB.
Installation
NOTE: When a new SJB is installed, all customer RKE transmitters may be required to program
the RKE transmitters to the new SJB.
1. NOTE: The SJB electrical connector levers must click into a fully released position before they
can be removed and must click into a fully closed
(connected) position when installing.
Position the SJB into the 2 locating pins and connect the 5 electrical connectors.
2. From under the instrument panel, install the SJB bolt. 3. Through the headlight switch bezel
opening, install the 2 SJB bolts. 4. If necessary, install the LH instrument panel side finish panel. 5.
Connect the 2 electrical connectors and install the headlight switch bezel assembly into the
instrument panel. 6. Position the parking brake control assembly and install the 3 bolts.
- Tighten to 20 Nm (15 lb-ft).
7. Install the harness clip on the parking brake cable housing. 8. Install the hood release cable
pushpin into the parking brake control bracket. 9. Connect the parking brake switch electrical
connector.
10. Position the parking brake release handle and install the 2 bolts. 11. Position the hood release
lever assembly and install the bolt.
12. NOTE: While installing the trim panel, pull the hood release lever rearward in order for the
release lever to slide through the trim panel.
Position the cowl side trim panel and install the pushpin.
13. Position the LH door opening weather seal. 14. Install the driver door scuff plate.
15. NOTE: When successful, this step provides the calibration necessary for SJB operation and
clears DTC B2477. The clearing of the DTC
indicates the calibration data has been successfully downloaded to the SJB.
Download the SJB configuration information from the diagnostic tool to the SJB.
16. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing
of these DTCs indicates the SJB has recognized
the tire pressure sensors during the training procedure.
Train the tire pressure sensors.
17. Clear the DTCs.
18. NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing
mode, and to be sure there are no other concerns with
the newly programmed SJB.
Carry out the SJB on-demand self-test.
19. NOTE: If the module configuration upload/download is successful, then the RKE transmitters
do not need to be reprogrammed to the vehicle.
However, if the module configuration upload/download is unsuccessful and as-built data must be
used to configure the module, then ALL of the customer's RKE transmitters must be reprogrammed
to the vehicle.
Program the RKE transmitters to the new SJB (if necessary).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module >
Component Information > Service and Repair
Auxiliary Step / Running Board Module: Service and Repair
RETRACTABLE RUNNING BOARD MODULE
Removal and Installation
1. Remove the RH C-pillar trim panel. 2. Disconnect the retractable running board module electrical
connectors. 3. Remove the 3 screws and the retractable running board module assembly.
- To install, tighten to 7 Nm (62 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Service and Repair
Auxiliary Step / Running Board Motor: Service and Repair
RETRACTABLE RUNNING BOARD MOTOR
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: If the retractable running board cannot be extracted, extend the running board by hand.
Extend the retractable running board.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor >
Component Information > Service and Repair > Page 8281
3. Remove the straps and disconnect the retractable running board motor electrical connector.
4. Remove the wedge screw and wedge. Note orientation for reinstallation.
- To install, tighten to 8 Nm (71 lb-in).
5. Remove the 3 bolts and retractable running board motor. 6. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Customer Interest: > 06-17-5 > Sep > 06 > Body - Poor Wheel Lip Molding To
Bumper Fascia Fit
Front Bumper Cover / Fascia: Customer Interest Body - Poor Wheel Lip Molding To Bumper Fascia
Fit
TSB 06-17-5
09/04/06
WHEEL LIP MOULDINGS - POOR FIT TO BUMPER FASCIA
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Explorer Sport Trac vehicles may exhibit
a poor fit condition between the front wheel lip moldings and bumper fascia.
ACTION Use the Service Procedure to adjust wheel lip moldings for improved fit.
SERVICE PROCEDURE
1. Remove the forward most front wheel lip push pin and discard.
2. From the Service Kit, install one (1) u-clip to the fender flange (Figure 1).
3. From the kit, align the u-clip and seat the nylon block in the wheel lip bracket access (Figure 1).
4. Use the screw and washer from the kit to secure the wheel lip molding and nylon block while
holding the fender wheel lip outboard to align it to the fascia wheel lip molding.
5. Continue to tighten the screw and push forward on wheel lip until the contour between fascia
wheel lip and fender wheel lip are aligned.
6. Repeat procedure on opposite side of vehicle, if necessary, to ensure consistent side to side fit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061705A 2006 Explorer 4dr / 0.2 Hr.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > Customer Interest: > 06-17-5 > Sep > 06 > Body - Poor Wheel Lip Molding To
Bumper Fascia Fit > Page 8292
Mountaineer, 2007 Explorer Sport Trac: Install Service Kit To Adjust Wheel Lip Molding(s) Includes
Time To Perform Operation On One Or Both Sides Of Vehicle.
DEALER CODING
CONDITION
BASIC PART NO. CODE
16A075 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > By Symptom: > 06-17-5 > Sep > 06 > Body - Poor Wheel Lip Molding To
Bumper Fascia Fit
Front Bumper Cover / Fascia: By Symptom Body - Poor Wheel Lip Molding To Bumper Fascia Fit
TSB 06-17-5
09/04/06
WHEEL LIP MOULDINGS - POOR FIT TO BUMPER FASCIA
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Explorer Sport Trac vehicles may exhibit
a poor fit condition between the front wheel lip moldings and bumper fascia.
ACTION Use the Service Procedure to adjust wheel lip moldings for improved fit.
SERVICE PROCEDURE
1. Remove the forward most front wheel lip push pin and discard.
2. From the Service Kit, install one (1) u-clip to the fender flange (Figure 1).
3. From the kit, align the u-clip and seat the nylon block in the wheel lip bracket access (Figure 1).
4. Use the screw and washer from the kit to secure the wheel lip molding and nylon block while
holding the fender wheel lip outboard to align it to the fascia wheel lip molding.
5. Continue to tighten the screw and push forward on wheel lip until the contour between fascia
wheel lip and fender wheel lip are aligned.
6. Repeat procedure on opposite side of vehicle, if necessary, to ensure consistent side to side fit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061705A 2006 Explorer 4dr / 0.2 Hr.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > By Symptom: > 06-17-5 > Sep > 06 > Body - Poor Wheel Lip Molding To
Bumper Fascia Fit > Page 8298
Mountaineer, 2007 Explorer Sport Trac: Install Service Kit To Adjust Wheel Lip Molding(s) Includes
Time To Perform Operation On One Or Both Sides Of Vehicle.
DEALER CODING
CONDITION
BASIC PART NO. CODE
16A075 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-17-5 > Sep > 06 > Body - Poor Wheel Lip
Molding To Bumper Fascia Fit
Front Bumper Cover / Fascia: All Technical Service Bulletins Body - Poor Wheel Lip Molding To
Bumper Fascia Fit
TSB 06-17-5
09/04/06
WHEEL LIP MOULDINGS - POOR FIT TO BUMPER FASCIA
FORD: 2006 Explorer 2007 Explorer Sport Trac
MERCURY: 2006 Mountaineer
ISSUE Some 2006 Explorer 4dr / Mountaineer and 2007 Explorer Sport Trac vehicles may exhibit
a poor fit condition between the front wheel lip moldings and bumper fascia.
ACTION Use the Service Procedure to adjust wheel lip moldings for improved fit.
SERVICE PROCEDURE
1. Remove the forward most front wheel lip push pin and discard.
2. From the Service Kit, install one (1) u-clip to the fender flange (Figure 1).
3. From the kit, align the u-clip and seat the nylon block in the wheel lip bracket access (Figure 1).
4. Use the screw and washer from the kit to secure the wheel lip molding and nylon block while
holding the fender wheel lip outboard to align it to the fascia wheel lip molding.
5. Continue to tighten the screw and push forward on wheel lip until the contour between fascia
wheel lip and fender wheel lip are aligned.
6. Repeat procedure on opposite side of vehicle, if necessary, to ensure consistent side to side fit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
061705A 2006 Explorer 4dr / 0.2 Hr.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-17-5 > Sep > 06 > Body - Poor Wheel Lip
Molding To Bumper Fascia Fit > Page 8304
Mountaineer, 2007 Explorer Sport Trac: Install Service Kit To Adjust Wheel Lip Molding(s) Includes
Time To Perform Operation On One Or Both Sides Of Vehicle.
DEALER CODING
CONDITION
BASIC PART NO. CODE
16A075 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8310
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8311
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8312
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8318
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8319
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8320
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8326
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8327
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 08-21-11 > Oct >
08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 8328
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures
Front Bumper Cover / Fascia: Procedures
TAB REPAIR - BUMPER
1. NOTE:
- Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of
appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a
new replacement bumper cover. If the bumper cover is determined to be repairable, proceed to the
following steps.
- The following steps are to be used as a guideline. Depending on what brand of adhesives, patch
material etc., are used, procedures may vary slightly.
Remove the affected bumper.
2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area
with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics
adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass
cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape
approximately 51 mm (2 in) from original tab.
6. Prepare the repair adhesive per manufacturer's instructions and apply to the affected area.
- Immediately apply the plastic repair material to form the tab shape.
7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme
care to not sand through the exterior surface. 8. Perform any required paint repair operations to the
bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures > Page 8331
Front Bumper Cover / Fascia: Removal and Replacement
FRONT BUMPER COVER
Explorer/Explorer Sport Trac
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures > Page 8332
Mountaineer
Exploded Views
Removal and Installation
Explorer
1. Remove the headlamp assemblies.
All vehicles
2. Disconnect the fog lamp electrical connectors, if equipped. 3. Disconnect the side turn signal
lamp electrical connectors, if equipped. 4. Remove the front fender inner splash shield screws. 5.
Remove the front fender inner splash shield pin-type retainers. 6. Remove the front fender inner
splash shields. 7. Remove the 2 bolts from the bottom of the bumper cover.
Explorer
8. Remove the 6 grille-to-grille opening panel scrivets.
NOTE: The fender clips are removed with the front fender. Use a flat-blade screwdriver to release
the locking tabs from the front bumper cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Procedures > Page 8333
9. Release the bumper cover-to-fender clips.
Mountaineer
10. Remove the bumper cover upper screws. 11. Rotate the bottom of the front bumper cover
upward. 12. Apply downward pressure to the top of the front bumper cover to release the 3 locking
tabs.
All vehicles
13. Remove the front bumper cover. 14. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System
Information > Service and Repair
Front Bumper Reinforcement: Service and Repair
Bumper - Front
Explorer/Explorer Sport Trac
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System
Information > Service and Repair > Page 8337
Mountaineer
Exploded Views
Removal and Installation
1. Remove the front bumper cover. 2. Remove the 4 front bumper bolts.
- To install, tighten to 48 Nm (35 lb-ft).
3. Remove the front bumper. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures
Rear Bumper Cover / Fascia: Procedures
TAB REPAIR - BUMPER
1. NOTE:
- Inspect the bumper cover to determine if part can be repaired to an acceptable level of quality of
appearance, fit and durability. Will labor and material cost of the repair meet or exceed the cost of a
new replacement bumper cover. If the bumper cover is determined to be repairable, proceed to the
following steps.
- The following steps are to be used as a guideline. Depending on what brand of adhesives, patch
material etc., are used, procedures may vary slightly.
Remove the affected bumper.
2. Clean the broken tab(s) with a plastics wax and grease remover. 3. Hand sand the repair area
with 80-grit sandpaper and remove any foreign material with compressed air. 4. Apply a plastics
adhesion promoter per label directions to the repair area. 5. Measure and cut a patch of fiberglass
cloth or equivalent large enough to form the front of the tab, then slope back in a wedge shape
approximately 51 mm (2 in) from original tab.
6. Prepare the repair adhesive per manufacturer's instructions and apply to the affected area.
- Immediately apply the plastic repair material to form the tab shape.
7. Allow appropriate cure time and shape the repair tab using a small angle sander. Use extreme
care to not sand through the exterior surface. 8. Perform any required paint repair operations to the
bumper cover using Ford-approved paint systems. 9. Reassemble and install the bumper cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8343
Rear Bumper Cover / Fascia: Removal and Replacement
BUMPER COVER - REAR, SPORT TRAC
Explorer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8344
Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8345
Explorer Sport Trac
Exploded View
Removal and Installation
1. Remove the 6. rear bumper cover screws.
- To install, tighten to 6 Nm (53 lb-in).
2. Remove the 6 rear bumper cover splash shield screws (3 each side). 3. Disconnect the license
plate electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Procedures > Page 8346
4. CAUTION: To avoid damaging the rear bumper cover, do not twist the cover when removing.
Remove the bumper cover. Pull the outer corners outward and pull the bumper cover rearward to disengage the cover from the
retaining clips.
5. Transfer the components as necessary. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
1. Remove the wiper pivot arms.
CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the
cowl panel.
2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl
panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining
clips. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
EXTERIOR FRONT DOOR HANDLE
Removal and Installation
1. Remove the front door trim panel. 2. Position the watershield aside. 3. Remove the screw and
the energy absorbing foam pad. 4. If equipped, disconnect the door lock cylinder actuating rod. 5.
Open the clip and disconnect the exterior front door handle actuating rod. 6. Remove the 2 exterior
front door handle nuts.
- To install, tighten to 9 Nm (80 lb-in).
7. Remove the exterior front door handle. 8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
INTERIOR DOOR HANDLE - FRONT
Removal and Installation
1. Remove the front door trim panel. 2. Remove the 3 screws and the interior front door handle. 3.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
FRONT DOOR LATCH
Removal and Installation
1. Remove the front door trim panel. 2. Position the watershield aside.
3. NOTE: Slide the foam insulating block forward to release the 2 clips.
Remove the screw and the energy absorbing foam pad.
4. Release the interior door handle actuating cable locator from the door frame. 5. Disconnect the
front door latch harness electrical connector and release the harness locator from the door frame.
6. Open the clip and disconnect the exterior front door handle actuating rod. 7. Release the front
door push button rod from the door frame retainer. 8. If equipped, disconnect the front door lock
cylinder actuating rod from the lock cylinder. 9. Remove the 3 screws and the front door latch.
- To install, tighten to 12 Nm (9 lb-ft).
10. To install, reverse the removal procedure.
- Lubricate the front door latch after installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
DOOR TRIM PANEL - FRONT
Removal and Installation
1. Remove the front door trim panel assist handle cover. 2. Remove the front door trim panel assist
handle screws. 3. Remove the front door trim panel handle bezel cover. 4. Remove the front door
trim panel handle bezel screws. 5. Remove the front door trim panel lower screws.
CAUTION: To avoid damaging the front door trim panel, do not pull the bottom of the panel
outward.
6. Remove the front door trim panel by lifting upward on the armrest to disengage the panel clips.
7. Disconnect the electrical connectors. 8. Disconnect the lock rod cable from the front door trim
panel. 9. Disconnect the door handle conduit and cable from the front door trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair > Page 8367
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System
Information > Adjustments
Front Door Striker: Adjustments
STRIKER ADJUSTMENT
1. Loosen the door latch striker plate bolts.
2. Adjust the door latch striker plate from side-to-side or up and down as necessary.
3. Tighten the door latch striker plate bolts.
- Tighten to 30 Nm (22 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
Front Door Window Glass Weatherstrip > Component Information > Service and Repair
Front Door Window Glass Weatherstrip: Service and Repair
DOOR GLASS TOP RUN - FRONT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 8375
Part 2
Exploded Views
Removal and Installation
1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door
glass top run channel assembly bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Remove the front door glass top run channel assembly through the top opening of the front door.
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair
Front Door Window Motor: Service and Repair
WINDOW REGULATOR MOTOR - FRONT DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Page 8379
Part 2
Exploded View
Removal and Installation
1. Remove the front door window regulator. 2. Remove the 3 front door window regulator motor
bolts.
- To install, tighten to 7 Nm (62 lb-in).
3. Remove the front door window regulator motor. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair
WINDOW REGULATOR - FRONT DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8383
Part 2
Exploded View
Removal and Installation
1. Remove the front door trim panel. 2. Remove the front door speaker. 3. Remove the exterior
mirror front door weather shield. 4. Disconnect the exterior mirror electrical connector.
5. Release the 3 door wiring harness pin-type retainers. 6. Remove the front door weather shield.
7. Remove the door trim panel reinforcement screw. 8. Remove the door trim panel reinforcement.
9. CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet
removal process. If the holes become
enlarged, the new rivets may become loose, resulting in a clicking noise concern.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
Remove the 2 front door window glass-to-regulator rivets. Position the front door window glass as necessary to access the front door window
glass-to-regulator rivets.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Page 8384
10. Secure the front door glass in the full up position with tape. 11. Disconnect the window
regulator motor electrical connector. 12. Remove the 5 window regulator assembly nuts.
- To install, tighten to 10 Nm (89 lb-in).
13. Remove the window regulator assembly. 14. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
EXTERIOR REAR DOOR HANDLE
Removal and Installation
1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Open the clip and
disconnect the exterior rear door handle actuating rod. 4. Remove the 2 nuts and the exterior rear
door handle.
- To install, tighten to 9 Nm (80 lb-in).
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
INTERIOR DOOR HANDLE - REAR
Removal and Installation
1. Remove the rear door trim panel. 2. Remove the 3 interior rear door handle screws and the
interior rear door handle. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Service and Repair
Rear Door Latch: Service and Repair
REAR DOOR LATCH
Removal and Installation
1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Release the interior door
handle actuating cable locator from the door frame. 4. Open the clip and disconnect the exterior
handle actuating rod. 5. Disconnect the rear door ajar switch and rear door lock actuator electrical
connectors. 6. Remove the 3 rear door latch screws.
- To install, tighten to 12 Nm (9 lb-ft).
7. Release the rear door push button rod from the door frame retainer. 8. To install, reverse the
removal procedure.
- Lubricate the door latch after installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
DOOR TRIM PANEL - REAR
Explorer/Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 8399
Explorer Sport Trac
Removal and Installation
1. Remove the rear door trim panel assist handle cover. 2. Remove the rear door trim panel assist
handle screws. 3. Remove the rear door trim panel handle bezel cover. 4. Remove the rear door
trim panel handle bezel screws. 5. Remove the rear door trim panel lower screw.
6. CAUTION: To avoid damaging the trim panel, do not pull the bottom of the panel outward.
Remove the rear door trim panel by lifting upward on the armrest to disengage the panel clips.
7. Disconnect the electrical connectors. 8. Disconnect the rod cable from the rear door trim panel.
9. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System
Information > Adjustments
Rear Door Striker: Adjustments
STRIKER ADJUSTMENT
1. Loosen the door latch striker plate bolts.
2. Adjust the door latch striker plate from side-to-side or up and down as necessary.
3. Tighten the door latch striker plate bolts.
- Tighten to 30 Nm (22 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
Rear Door Window Glass Weatherstrip > Component Information > Service and Repair
Rear Door Window Glass Weatherstrip: Service and Repair
DOOR GLASS TOP RUN - REAR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Page 8407
Part 2
Exploded View
Removal and Installation
1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door
glass top run assembly bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Remove the rear door glass top run channel assembly.
- Remove the rear door glass top run channel assembly through the top opening of the rear door.
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 Motor: Service and Repair
WINDOW REGULATOR MOTOR - REAR DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Service and Repair > Page 8411
Part 2
Exploded View
Removal and Installation
1. Remove the interior moulding. 2. Remove the rear door trim panel and weather shield. 3.
Remove the 3 window regulator motor bolts.
- To install, tighten to 7 Nm (62 lb-in).
4. Remove the window regulator motor. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair
Rear Door Window Regulator: Service and Repair
WINDOW REGULATOR - REAR DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Service and Repair > Page 8415
Part 2
Exploded View
Removal and Installation
1. Remove the rear door trim panel. 2. Remove the rear door speaker. 3. Remove the interior
moulding. 4. Remove the rear door weather shield.
5. CAUTION: Make sure the hole in the glass bracket does not become enlarged during the rivet
removal process. If the hole becomes
enlarged, the new rivet may become loose, resulting in a clicking noise concern.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
Remove the rear door window glass-to-regulator rivet. Position the rear door window glass as necessary to access the rear door window
glass-to-regulator rivet.
6. Secure the rear door window glass in the full up position with tape. 7. Disconnect the window
regulator motor electrical connector. 8. Remove the 2 window regulator nuts.
- To install, tighten to 10 Nm (89 lb-in).
9. Remove the 3 window regulator motor bracket nuts.
- To install, tighten to 10 Nm (89 lb-in).
10. Remove the window regulator assembly. 11. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair
Hood Latch: Service and Repair
HOOD LATCH
Removal and Installation
NOTE: Mark the position of the hood latch prior to removing the hood latch bolts to aid positioning
during installation.
1. Remove the 2 hood latch bolts.
- To install, tighten to 12 Nm (9 lb-ft).
2. Disconnect the hood latch release cable from the hood latch and remove the latch. 3. To install,
reverse the removal procedure.
- Check the latch adjustment to make sure the latch was installed and aligned correctly.
- Lubricate the hood latch after installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
HOOD LATCH RELEASE HANDLE
Removal and Installation
1. Remove the hood latch. 2. Remove the screw and the hood latch release handle. 3. Remove the
pin-type retainer and the LH A-pillar lower trim panel. 4. Remove the hood latch release cable
assembly screw. 5. Release the hood latch release cable from the 4 cable locators and remove the
cable. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
WINDOW GLASS - LIFTGATE
Material
Material
Removal and Installation
1. If installing a new liftgate window glass, remove the rear window wiper motor. 2. Position the
liftgate trim panel aside to access the liftgate window glass electrical connectors and the 2 liftgate
window glass hinge-to-glass screws. 3. Disconnect the liftgate window glass electrical connectors.
4. CAUTION: Open and support the liftgate window glass before removing the liftgate window glass
struts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair > Page 8427
Remove the liftgate window glass struts. To avoid breaking the liftgate window glass, disconnect the liftgate window glass struts from the
liftgate window glass before disconnecting the liftgate window glass struts from the rear liftgate.
5. Remove the 2 liftgate hinge-to-glass screws.
- Apply threadlock into the liftgate window glass hinge-to-glass bolt hole, making sure that the
threadlock is on the threads.
- To install, tighten to 10 Nm (89 lb-in).
6. With the help of an assistant, remove the liftgate window glass. 7. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Service and Repair > Liftgate Latch Actuator
Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Latch Actuator
LIFTGATE LATCH ACTUATOR
Removal and Installation
1. Remove the liftgate latch. 2. Release the locking tab and remove the liftgate latch actuator. 3. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Service and Repair > Liftgate Latch Actuator > Page 8432
Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Window Latch Actuator
LIFTGATE WINDOW LATCH ACTUATOR
Removal and Installation
1. Remove the liftgate window latch. 2. Remove the 3 screws and the liftgate window latch
actuator. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Service and Repair
Trunk / Liftgate Handle: Service and Repair
LIFTGATE RELEASE HANDLE
Removal and Installation
1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate
release handle actuating rod. 4. Remove the 2 liftgate release handle screws. 5. Remove the
liftgate release handle. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim
Panel > Component Information > Service and Repair
Trunk / Liftgate Interior Trim Panel: Service and Repair
LIFTGATE TRIM PANEL
Removal and Installation
1. Remove the 2 liftgate grab handle screws. 2. Remove the liftgate grab handle.
3. CAUTION: To avoid damaging the trim panel, do not pull the bottom of the panel outward.
Lift the liftgate trim panel by lifting upward to disengage the clips and remove the panel. Disconnect the liftgate trim panel electrical connector.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
LIFTGATE LATCH
Removal and Installation
1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate
release handle actuating rod. 4. Disconnect the liftgate latch actuator and the liftgate ajar switch
electrical connectors. 5. Remove the 3 liftgate latch screws and remove the latch.
- To install, tighten to 12 Nm (9 lb-ft).
6. To install, reverse the removal procedure.
- Lubricate the liftgate latch after installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 8443
Trunk / Liftgate Latch: Service and Repair Liftgate Window Latch
LIFTGATE WINDOW LATCH
Removal and Installation
1. Remove the liftgate trim panel. 2. Position the watershield aside. 3. Disconnect the liftgate
window actuator and liftgate window ajar switch electrical connectors. 4. Remove the 4 screws and
the liftgate window latch.
- To install, tighten to 12 Nm (9 lb-ft).
5. To install, reverse the removal procedure.
- Lubricate the liftgate window latch after installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
TAILGATE LOCK CYLINDER
Removal and Installation
NOTE:
- When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the
ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits
only 1 lock. If a new key is to be used, the new key code is attached to a tag.
- The individual door lock cylinders are 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 a new lock cylinder to the current key code of the
vehicle.
1. Remove the tailgate release handle. 2. Remove retaining clip and the tailgate lock cylinder. 3. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
1. Remove the wiper pivot arms.
CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the
cowl panel.
2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl
panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining
clips. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Explorer/Explorer Sport Trac
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Page 8456
Mountaineer
Exploded View
Removal and Installation
1. Loosen the running board bolts and lower the running board to access the front fender moulding
pin-type retainer.
- To install, tighten to 23 Nm (17 lb-ft).
2. Remove the lower pin-type retainer from the front fender moulding. 3. Remove the 2 rear
pin-type retainers from the front fender moulding.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Page 8457
4. Position the front fender moulding aside and remove the splash shield lower screw. 5. Remove
the front splash shield screws. 6. Remove the front splash shield pin-type retainers. 7. Remove the
front splash shield. 8. Remove the front fender splash shield. 9. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service
and Repair
Rear Fender Liner: Service and Repair
PICKUP BED WHEEL HOUSE
Removal and Installation
RH and LH
1. Remove the rear fender moulding.
2. NOTE: LH shown, RH similar.
Remove the 3 bumper cover screws.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service
and Repair > Page 8462
3. NOTE: RH shown, LH similar.
Remove the 4 rear wheel house-to-wheel house opening screws.
RH only
4. Remove the pin-type retainer.
RH and LH
5. NOTE: RH shown, LH similar.
Remove the rear wheel house. Remove the screws.
- Remove the rear wheel house.
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Explorer / Mountaineer
Body / Frame Mount Bushing: Description and Operation Explorer / Mountaineer
FRAME AND BODY MOUNTING
The frame consists of 2 steel channel rails, 9 crossmembers for Explorer Sport Trac or 8
crossmembers for Explorer/Mountaineer including a front crossmember, transmission support
crossmember and a rear crossmember (trailer hitch). New side rails and welded crossmembers,
including the trailer hitch, are not installed separately. A front frame rail repair kit is available if the
front rail is to be repaired and a rear crossmember (hitch) repair kit is available if the rear
crossmember or rail is to be repaired.
The 1B crossmember and transmission crossmember are included in assembly to the frame but
can be serviced separately.
Frame-Mounted Heat Shields
Structural Enhancement - Explorer/Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Explorer / Mountaineer > Page 8468
Structural Enhancement - Explorer Sport Trac
The frame-mounted heat shields are attached to the top of the frame and crossmembers with bolts.
The body must be lifted off the frame enough for access to the bolts that attach the heat shields to
the top of the frame.
The purpose of these inserts is to enhance the structural rigidity of the frame in this area. The
inserts cannot be replaced or repaired.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Explorer / Mountaineer > Page 8469
Body / Frame Mount Bushing: Description and Operation Frame and Body Mounting
Frame and Body Mounting
The frame consists of 2 steel channel rails, 9 crossmembers for Explorer Sport Trac or 8
crossmembers for Explorer/Mountaineer including a front crossmember, transmission support
crossmember and a rear crossmember (trailer hitch). New side rails and welded crossmembers,
including the trailer hitch, are not installed separately. A front frame rail repair kit is available if the
front rail is to be repaired and a rear crossmember (hitch) repair kit is available if the rear
crossmember or rail is to be repaired.
The 1B crossmember and transmission crossmember are included in assembly to the frame but
can be serviced separately.
Frame-Mounted Heat Shields
The frame-mounted heat shields are attached to the top of the frame and crossmembers with bolts.
The body must be lifted off the frame enough for access to the bolts that attach the heat shields to
the top of the frame.
Structural Enhancement - Explorer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Description and Operation > Explorer / Mountaineer > Page 8470
Structural Enhancement - Explorer Sport Trac
The purpose of these inserts is to enhance the structural rigidity of the frame in this area. The
inserts cannot be replaced or repaired.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Body Support - Number 1
Removal and Installation
CAUTION: When removing upper body mounts, all other body mount support bolts must be loose
before raising the vehicle body from the frame, to prevent damage occurring to the vehicle.
NOTE:
- Body mounts must be held with a wrench on the bottom while loosening the bolt from the top.
- 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 mount support installation.
1. Remove the scuff plate trim panels. 2. Remove the cowl side trim panels. 3. Position the
carpeting aside and remove the body insulator plug button. 4. Remove the body support bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8473
- To install, tighten to 90 Nm (66 lb-ft).
5. Remove the body support washer. 6. Remove the body support nuts.
- To install, tighten to 103 Nm (76 lb-ft).
7. Remove the upper body mount. 8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8474
Body / Frame Mount Bushing: Service and Repair Body Support - Number 2
Body Support - Number 2
Body Support - Number 2
Removal and Installation
CAUTION: When removing upper body mounts, enough adjacent body mount support bolts or nuts
must be removed to prevent damage occurring to the vehicle.
NOTE:
- Body mounts must be held with a wrench on the bottom while loosening the bolt from the top.
- 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 mount support installation.
1. Remove front seat. 2. Remove the B-pillar trim panel. 3. Position the carpet aside and remove
the body insulator plug button. 4. Remove the body support bolt.
- To install, tighten to 90 Nm (66 lb-ft).
5. Remove the body support washer. 6. Remove the lower body support mount. 7. Remove enough
adjacent body mount bolts to allow for the removal of the upper half of the mount without damaging
the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8475
8. Carefully raise the vehicle body enough to remove the upper body mount. 9. Remove the upper
body mount.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8476
Body / Frame Mount Bushing: Service and Repair Body Support - Number 3
Body Support - Number 3
Body Support - Number 3 (Explorer/Mountaineer)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8477
Body Support - Number 3 (Explorer Sport Trac)
CAUTION: When removing upper body mounts, enough adjacent body mount support bolts and
nuts must removed to prevent damage occurring to the vehicle.
NOTE:
- Body mounts must be held with a wrench on the bottom while loosening the bolt from the top.
- 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 mount support installation.
Explorer and Mountaineer only
1. Remove the rear seat. 2. Remove the B-pillar trim panel.
Explorer Sport Trac only
3. Remove the scuff plate trim panels. 4. Remove the cowl side trim panels.
All vehicles
5. Position the carpet aside and remove the body insulator plug button. 6. Remove the body
support bolt.
- To install, tighten to 90 Nm (66 lb-ft).
7. Remove the body support washer.
Explorer and Mountaineer only
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8478
8. Remove the lower body support mount.
Explorer Sport Trac only
9. Remove enough adjacent body mount bolts to allow for the removal of the upper half of the
mount without damaging the vehicle.
All vehicles
10. Carefully raise the vehicle body enough to remove the upper body mount.
Explorer Sport Trac only
11. Remove the body support nuts and remove the lower body mount.
- To install, tighten to 103 Nm (76 lb-ft).
All vehicles
12. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8479
Body / Frame Mount Bushing: Service and Repair Body Support - Number 4
Body Support - Number 4
Body Support - Number 4
Removal and Installation
CAUTION: When removing upper body mounts, enough adjacent body mount support bolts or nuts
must be removed to prevent damage occurring to the vehicle.
NOTE:
- Body mounts must be held with a wrench on the bottom while loosening the bolt from the top.
- 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 mount support installation.
1. Position the rear storage compartment trim cover open and remove the body insulator plug
button. 2. Remove the body support bolt.
- To install, tighten to 90 Nm (66 lb-ft).
3. Remove the body support washer. 4. Remove the lower body support mount. 5. Remove enough
adjacent body mount bolts to allow for the removal of the upper part of the mount without damaging
the vehicle. 6. Carefully raise the vehicle body enough to remove the upper body mount. 7.
Remove the upper body mount.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8480
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8481
Body / Frame Mount Bushing: Service and Repair Body Support - Front End Sheet Metal
Body Support - Front End Sheet Metal
Body Support Front End Sheet Metal
Removal and Installation
CAUTION: When removing the front upper body mounts, enough adjacent body mount support
bolts or nuts must be removed to prevent damage occurring to the vehicle.
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 mount support installation.
1. Remove the body support nut.
- To install, tighten to 55 Nm (41 lb-ft).
2. Remove the body support washer. 3. Remove the body support bolt.
- To install, tighten to 55 Nm (41 lb-ft).
4. Remove the front end sheet metal body support lower mount.
5. NOTE: Body mounts must be held with a wrench on the bottom while loosening the nuts from
the top.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 8482
Remove enough adjacent body mount bolts to allow for the removal of the upper half of the mount
without damaging the vehicle.
6. Carefully raise the vehicle body enough to remove the front end sheet metal body support upper
mount. 7. Remove the front end sheet metal body support upper mount. 8. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information >
Service and Repair > Crossmember - 1B
Rear Cross-Member: Service and Repair Crossmember - 1B
CROSSMEMBER - 1B
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 crossmember bolts. 3.
Remove the 4 crossmember nuts.
- To install, tighten to 103 Nm (76 lb-ft).
4. Remove the 1B crossmember. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information >
Service and Repair > Crossmember - 1B > Page 8488
Rear Cross-Member: Service and Repair Transmission Support Crossmember
TRANSMISSION SUPPORT CROSSMEMBER
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 transfer case skid plate
bolts and remove the transfer case skid plate.
- To install, tighten to 15 Nm (11 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information >
Service and Repair > Crossmember - 1B > Page 8489
3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar.
Remove the heat shield bolt from the RH heat shield. To install, tighten to 18 Nm (13 lb-ft).
4. Remove the heat shield bolt from the LH heat shield.
- To install, tighten to 18 Nm (13 lb-ft).
5. Support the transmission with a suitable jack. 6. Remove the 2 transmission mount nuts.
- To install, tighten to 90 Nm (66 lb-ft).
7. Remove the 6 transmission crossmember lower bolts.
- To install, tighten to 80 Nm (59 lb-ft).
8. NOTE: Tighten the nut side of the joint.
Remove the 2 upper nuts and 2 bolts from the transmission crossmember. To install, tighten to 143 Nm (105 lb-ft).
9. Remove the transmission crossmember. 10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair
Trailer Hitch: Service and Repair
Trailer Hitch
Material
Removal and Installation
NOTE: The factory rear trailer hitch crossmember is welded to the frame. The service replacement
trailer hitch crossmember will be bolted to the frame.
All vehicles
1. Remove the spare tire. 2. Remove the rear bumper cover. 3. Disconnect the trailer wiring
harness.
Explorer/Mountaineer
4. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg.
- Use Explorer/Mountaineer template No. 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
8493
EXPLORER/MOUNTAINEER TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
5. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- For the inboard side use Explorer/Mountaineer template No. 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
8494
EXPLORER/MOUNTAINEER TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- For the outboard side use Explorer/Mountaineer template No. 3.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
8495
EXPLORER/MOUNTAINEER TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND
INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
Explorer Sport Trac
6. Cut the rear rails vertically at least 10-18 mm (0.39-0.70 in) behind the rear body/box mount leg.
- Use Sport Trac template No. 1.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
8496
SPORT TRAC TEMPLATE # 1, LEFT HAND INNER SIDE VIEW, RIGHT HAND
SYMMETRICALLY OPPOSITE
7. Drill 18 mm (0.688 in) diameter holes for the inboard and outboard attachments to each frame
rail.
- Use Sport Trac Template No. 2.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
8497
SPORT TRAC TEMPLATE # 2, LEFT HAND INNER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
- Use Sport Trac template No. 3.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
8498
SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER
SYMMETRICALLY OPPOSITE TO LEFT HAND INNER
All vehicles
8. De-burr the cut edges of the frame rail and the drilled holes. 9. Clean the inner and outer
surfaces of the frame rails, making sure all mating surfaces are free of foreign material.
10. Apply 3 even coats of the specified anti-corrosion coating onto the inner and outer surfaces of
the frame rails where bare metal is present.
11. NOTE: It may be necessary to spread apart pull together the frame rails slightly to get brackets
to fit.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page
8499
Insert the new trailer hitch cross member assembly into the frame.
12. Hand start all 8 bolts into the weld nuts in the hitch brackets. 13. Tighten the inboard bolts.
- Tighten to 235 Nm (174 lb-ft).
14. Tighten the outboard bolts.
- Tighten to 235 Nm (174 lb-ft).
15. Install the trailer wiring harness. 16. Install the rear bumper cover. 17. Install the spare tire.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page
8503
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Customer
Interest: > 08-10-4 > May > 08 > Body - Chrome Grille Peeling/Blistering/Wrinkling
Grille: Customer Interest Body - Chrome Grille Peeling/Blistering/Wrinkling
TSB 08-10-4
05/26/08
CHROME GRILLE - PEELING, BLISTERING OR WRINKLING
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
ISSUE Some 2006-2008 Explorer 4dr and 2007-2008 Explorer Sport Trac vehicles may exhibit a
peeling, blistering or wrinkling chrome grille.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
BEFORE ORDERING A CHROME GRILLE VERIFY THE CONCERN IS COVERED UNDER
SERVICE WARRANTY BY REVIEWING THE PARTS AND SERVICE-WARRANTY
GUIDELINE-JOB AIDS-GRILLE PICTURE DICTIONARY: REFER TO THE BUMPER PICTURE
DICTIONARY ON THE WEBSITE FOR EXAMPLES OF WARRANTABLE AND
NON-WARRANTABLE CONDITIONS.
SERVICE PROCEDURE
Replace the grille using Work Shop Manual (WSM), Section 501-08.
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
081004A 2006-2008 Explorer, 1.2 Hrs.
2007-2008 Explorer Sport Trac: Replace Grille, Includes Time To Remove And Install Bumper
Cover (Do Not Use With 8200A, 17957A, 13007C)
DEALER CODING
CONDITION
BASIC PART NO. CODE
8200 34
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 08-10-4 > May > 08 > Body - Chrome Grille Peeling/Blistering/Wrinkling
Grille: All Technical Service Bulletins Body - Chrome Grille Peeling/Blistering/Wrinkling
TSB 08-10-4
05/26/08
CHROME GRILLE - PEELING, BLISTERING OR WRINKLING
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
ISSUE Some 2006-2008 Explorer 4dr and 2007-2008 Explorer Sport Trac vehicles may exhibit a
peeling, blistering or wrinkling chrome grille.
ACTION Follow the Service Procedure steps to correct the condition.
NOTE
BEFORE ORDERING A CHROME GRILLE VERIFY THE CONCERN IS COVERED UNDER
SERVICE WARRANTY BY REVIEWING THE PARTS AND SERVICE-WARRANTY
GUIDELINE-JOB AIDS-GRILLE PICTURE DICTIONARY: REFER TO THE BUMPER PICTURE
DICTIONARY ON THE WEBSITE FOR EXAMPLES OF WARRANTABLE AND
NON-WARRANTABLE CONDITIONS.
SERVICE PROCEDURE
Replace the grille using Work Shop Manual (WSM), Section 501-08.
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
081004A 2006-2008 Explorer, 1.2 Hrs.
2007-2008 Explorer Sport Trac: Replace Grille, Includes Time To Remove And Install Bumper
Cover (Do Not Use With 8200A, 17957A, 13007C)
DEALER CODING
CONDITION
BASIC PART NO. CODE
8200 34
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Grille: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Grille: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 8522
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Grille: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 8528
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 8529
Grille: Service and Repair
RADIATOR GRILLE - EXPLORER, EXPLORER SPORT TRAC
Removal and Installation
1. Remove the front bumper cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Technical Service Bulletins > Page 8530
2. Remove the 2 grille-to-bumper cover screws.
3. Remove the front bumper isolator and absorber.
1. Remove the 2 pushpins. 2. Remove the 2 nuts.
4. Remove the 4 scrivets. 5. Carefully release the 14 clips and remove the grille assembly from the
bumper cover. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door
Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Removal and Installation
1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3.
Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 8537
Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Removal and Installation
1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch
counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 8538
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Removal and Installation
1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch
counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp Switch > Component
Information > Service and Repair > Door Ajar Switch - Front Door > Page 8539
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Removal and Installation
1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and
remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Special Tool(s)
Special Tool(s)
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box
(SJB), located below the LH side of the instrument panel, remove the cover and the restraints
control module (RCM)
fuse 17 (10A) from the SJB.
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 switch to OFF.
6. WARNING: To avoid accidental deployment and possible personal 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
servicing, 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.
The front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8545
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.
2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the
cover.
4. 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.
5. Prove out the SRS as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8546
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment, which can result in personal injury.
- The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always
wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never
probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in
pretensioner, adaptive load limiting retractor or air bag deployment and could 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 reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8547
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart
junction box (SJB), located below the LH side of the instrument panel, remove the cover and the
restraints control module (RCM)
fuse 17 (10A) from the SJB.
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 front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
7. Remove the 2 driver air bag module bolts (1 shown).
8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation.
Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8548
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
10. Open and lower the glove compartment door.
11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield.
12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive
tether squibs do not require deactivation.
Through the glove compartment opening, disconnect the LH side passenger air bag module
electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector on the LH side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8549
14. From under the rear of the passenger seat, detach the passenger seat side air bag module
electrical connector from the seat track bracket. Then
slide and disengage the passenger seat side air bag module electrical connector locking clip, and
then release the tab and disconnect the passenger seat side air bag module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Vehicles without safety canopy modules
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM.
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Explorer and Mountaineer vehicles with safety canopy modules
17. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8550
18. Disconnect the passenger side safety canopy module electrical connector.
19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
20. Release and position aside the driver side C-pillar trim panel.
21. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8551
22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles with safety canopy modules
23. Remove the driver and passenger side upper C-pillar trim panels.
24. Disconnect the passenger side safety canopy module electrical connector.
25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
26. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8552
27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles
28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module
electrical connector locking clip, and then release
the tab and disconnect the driver seat side air bag module electrical connector.
29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the
battery ground cable.
Reactivation
All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8553
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side
air bag module electrical connector.
4. Connect the driver seat side air bag module electrical connector and then slide and engage the
seat side air bag electrical connector locking clip.
Explorer Sport Trac vehicles with safety canopy modules
5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
6. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8554
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy module electrical connector.
8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and
passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles with safety canopy modules
10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
11. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8555
12. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
side safety canopy module electrical connector.
14. Connect the passenger side safety canopy module electrical connector.
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8556
16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
seat side air bag module electrical connector.
17. Connect the passenger seat side air bag module electrical connector and then slide and
engage the seat side air bag electrical connector locking
clip. Then attach the passenger seat side air bag module electrical connector to the seat track
bracket.
18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector on the LH side.
19. Connect the LH side passenger air bag module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8557
20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21.
Close glove compartment door.
22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the
driver air bag module in the wrong
position. Match the electrical connector key to the keyway in the driver air bag module. Do not force
the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted in removal.
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering > Page 8558
25. 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.
26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and
install the cover.
28. 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.
29. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch back to ON and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a
scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair
Headliner: Service and Repair
HEADLINER
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 8562
Explorer/Mountaineer (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 8563
Explorer Sport Trac
Removal and Installation
Explorer and Mountaineer only
1. If equipped, remove the rear entertainment system.
Explorer Sport Trac only
2. NOTE: The headliner is removed through the rear passenger door. To facilitate removal, the
front passenger seat must be removed.
Remove the front passenger seat.
All vehicles
3. Remove the overhead console. 4. Remove the A-pillar trim panel. 5. Position the B-pillar upper
trim panel aside.
Explorer and Mountaineer only
6. Remove the C-pillar trim panel. 7. Remove the D-pillar trim panel.
Explorer Sport Trac
8. Position the C-pillar upper trim panel aside.
All vehicles
9. Remove the gimp around the roof opening panel, if equipped.
10. Remove the 4 sun visor retainer screws. 11. Remove the sun visors. 12. Carefully lower the
headliner at the corner of the sun visor location to access the electrical connector and disconnect
the electrical connector. 13. Disconnect the roof opening panel, if equipped. 14. Disconnect the
interior mirror electrical connector and electronic compass sensor connector, if equipped. 15. Use a
thin-blade tool and carefully remove the dome lamp cover. 16. Disconnect the dome lamp electrical
connectors.
Explorer and Mountaineer only
17. Remove the upper air duct.
- Remove the pin-type retainers.
- Push down on the duct, tilt the top outward and pull upward to remove.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 8564
18. Remove the lower air duct.
19. Disconnect the electrical connector located at the C-pillar.
- Release the wiring harness pin-type retainers.
20. Disconnect all the electrical connectors.
All vehicles
21. Disconnect the electrical connector and the wiring pin-type retainers on the A-pillar.
22. CAUTION: To prevent bending or damaging the headliner, an assistant is required to support
the headliner while carrying out the
remaining steps.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 8565
Open the sun visor center retainer cover and remove the screw.
23. Remove the sun visor center retainer. 24. Remove the rear pin-type retainer.
25. CAUTION: To prevent damaging the garment hanger retainer, use a 3/16-inch flat-blade
screwdriver to carry out this step.
NOTE: The garment hanger is shown without the roof sheet metal screw to show the metal retainer
clip. The metal retainer clip will remain engaged in the sheet metal after the garment hanger is
removed.
Remove the garment hangers. 1. Open the access door. 2. Insert the flat-blade screwdriver fully
into the garment hanger slot. 3. Rotate the screwdriver 90 degrees so that the screwdriver spreads
the metal retainer clip. Remove the plastic garment hanger.
26. NOTE: The headliner is removed through the passenger rear door for Explorer Sport Trac.
Remove the headliner.
27. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical
Service Bulletins > Customer Interest for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked
Sun Visor: Customer Interest Interior - Sun Visor Mirror Cover Cracked
TSB 09-2-9
02/09/09
SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008
FORD: 2007-2009 Explorer Sport Trac, Explorer
MERCURY: 2007-2009 Mountaineer
ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color
sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor
mirror cover hinge.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Replace all affected sun visors with new updated parts.
2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical
connector.
3. To install, reverse the removal procedure.
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
090209A 2007-2009 Explorer, 0.3 Hr.
Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A)
090209B 2007-2009 Explorer, 0.4 Hr.
Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A)
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical
Service Bulletins > Customer Interest for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page
8574
CONDITION
BASIC PART NO. CODE
7804104 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover
Cracked
Sun Visor: All Technical Service Bulletins Interior - Sun Visor Mirror Cover Cracked
TSB 09-2-9
02/09/09
SUN VISOR MIRROR COVER CRACKING - BUILT BETWEEN 1/212007 AND 11/3/2008
FORD: 2007-2009 Explorer Sport Trac, Explorer
MERCURY: 2007-2009 Mountaineer
ISSUE Some 2007-2009 Explorer, Mountaineer and Sport Trac vehicles equipped with camel color
sun visors built between 1/2/2007 and 11/3/2008 may exhibit a crack in the plastic at the sun visor
mirror cover hinge.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Replace all affected sun visors with new updated parts.
2. Remove the two (2) sun visor screws on the affected side and disconnect the electrical
connector.
3. To install, reverse the removal procedure.
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
090209A 2007-2009 Explorer, 0.3 Hr.
Mountaineer, Sport Trac: Replace ONE Sun Visor (Do Not Use With 04104A)
090209B 2007-2009 Explorer, 0.4 Hr.
Mountaineer, Sport Trac: Replace BOTH Sun Visors (Do Not Use With 04104A)
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover
Cracked > Page 8580
CONDITION
BASIC PART NO. CODE
7804104 D4
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel
Trim Panel: Service and Repair A - Pillar Trim Panel
A-PILLAR TRIM PANEL
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8585
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the 2 assist handle bolt covers. 2. Remove the 2 assist handle bolts.
- To install, tighten to 10 Nm (89 lb-in).
3. Remove the assist handle. 4. Position the door opening weatherstrip aside.
5. NOTE: The clip on the LH A-pillar trim panel must remain in the sheet metal. The clip comes off
the A-pillar trim panel when the panel is
removed.
Remove the A-pillar trim panel.
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8586
Trim Panel: Service and Repair B-Pillar Lower Trim Panel
B-PILLAR LOWER TRIM PANEL
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8587
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the front and rear door scuff plates. 2. Position the door opening weatherstrip aside. 3.
Remove the B-pillar lower trim panel. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8588
Trim Panel: Service and Repair B-Pillar Upper Trim Panel
B-PILLAR UPPER TRIM PANEL
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8589
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the B-pillar lower trim panel. 2. Remove the D-ring safety belt anchor bolt.
- To install, tighten to 40 Nm (30 lb-ft).
3. Position the door opening weatherstrip aside.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8590
4. Remove the B-pillar upper trim panel retaining clip from the lower right corner of the panel.
5. Remove the B-pillar upper trim panel retaining clip from the upper left of the panel. 6. To install,
reverse the removal procedure.
- Be sure the hole on the back of the B-pillar upper trim panel is seated over the safety belt D-ring
bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8591
Trim Panel: Service and Repair C-Pillar Lower Trim Panel - Explorer Sport Trac
C-PILLAR LOWER TRIM PANEL - EXPLORER SPORT TRAC
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8592
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the rear seat. 2. Remove the rear cab trim panel. 3. Remove the C-pillar lower safety
belt anchor bolt.
- To install, tighten to 40 Nm (30 lb-ft).
4. Position the door opening weatherstrip aside. 5. Remove the C-pillar lower trim panel. 6. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8593
Trim Panel: Service and Repair
A - Pillar Trim Panel
A-PILLAR TRIM PANEL
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8594
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the 2 assist handle bolt covers. 2. Remove the 2 assist handle bolts.
- To install, tighten to 10 Nm (89 lb-in).
3. Remove the assist handle. 4. Position the door opening weatherstrip aside.
5. NOTE: The clip on the LH A-pillar trim panel must remain in the sheet metal. The clip comes off
the A-pillar trim panel when the panel is
removed.
Remove the A-pillar trim panel.
6. To install, reverse the removal procedure.
B-Pillar Lower Trim Panel
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8595
B-PILLAR LOWER TRIM PANEL
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8596
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the front and rear door scuff plates. 2. Position the door opening weatherstrip aside. 3.
Remove the B-pillar lower trim panel. 4. To install, reverse the removal procedure.
B-Pillar Upper Trim Panel
B-PILLAR UPPER TRIM PANEL
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8597
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8598
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the B-pillar lower trim panel. 2. Remove the D-ring safety belt anchor bolt.
- To install, tighten to 40 Nm (30 lb-ft).
3. Position the door opening weatherstrip aside.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8599
4. Remove the B-pillar upper trim panel retaining clip from the lower right corner of the panel.
5. Remove the B-pillar upper trim panel retaining clip from the upper left of the panel. 6. To install,
reverse the removal procedure.
- Be sure the hole on the back of the B-pillar upper trim panel is seated over the safety belt D-ring
bolt.
C-Pillar Lower Trim Panel - Explorer Sport Trac
C-PILLAR LOWER TRIM PANEL - EXPLORER SPORT TRAC
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8600
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8601
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the rear seat. 2. Remove the rear cab trim panel. 3. Remove the C-pillar lower safety
belt anchor bolt.
- To install, tighten to 40 Nm (30 lb-ft).
4. Position the door opening weatherstrip aside. 5. Remove the C-pillar lower trim panel. 6. To
install, reverse the removal procedure.
C-Pillar Upper Trim Panel - Explorer Sport Trac
C-PILLAR UPPER TRIM PANEL - EXPLORER SPORT TRAC
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8602
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8603
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the C-pillar lower trim panel. 2. Remove the roof trim panel. 3. Remove the C-pillar
upper trim panel.
- Route the safety belt through the upper trim panel.
4. To install, reverse the removal procedures.
Cab Rear Trim Panel
CAB REAR TRIM PANEL
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8604
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Position the second row seat back forward.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8605
2. Remove the 2 screws from the storage compartment.
3. NOTE: When removing the cab rear trim panel, start in the upper left corner, moving clockwise
and remove the panel from the retaining clips.
Remove the rear trim panel.
4. To install, reverse the removal procedures.
Cowl Side Trim Panel
COWL SIDE TRIM PANEL
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8606
Explorer Sport Trac
Exploded Views
Removal and Installation
All vehicles
1. Remove the front door scuff plate.
Passenger side
2. Remove the cowl trim panel.
Driver side
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8607
3. Remove the hood release lever.
1. Remove the screw. 2. Remove the hood release lever.
4. Remove the cowl trim panel.
1. Remove the pin-type retainer. 2. Remove the cowl trim panel.
All vehicles
5. To install, reverse the removal procedure.
D-Pillar Trim Panel
D-PILLAR TRIM PANEL
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8608
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8609
Explorer Sport Trac
Exploded Views
Removal and Installation
Vehicles with third row seating
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8610
1. Remove the rear cargo management system.
- Remove the screw.
- Remove the pushpin.
- Remove the system.
2. Remove the D-pillar lower safety belt anchor bolt.
- To install, tighten to 40 Nm (30 lb-ft).
All vehicles
3. Position the liftgate opening weatherstrip aside.
4. Remove the rear upper headliner trim panel. 5. Remove the D-pillar trim panel. 6. To install,
reverse the removal procedure.
Quarter Trim Panel
QUARTER TRIM PANEL
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8611
Explorer And Mountaineer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8612
Explorer Sport Trac
Exploded Views
Removal and Installation
1. Remove the rear door scuff plate. 2. Remove the C-pillar trim panel. 3. Remove the D-pillar trim
panel. 4. Remove the liftgate scuff plate trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A - Pillar Trim Panel > Page 8613
5. Remove the luggage compartment assembly cover, if equipped. 6. Remove the stowage
compartment doors. 7. Position the carpet aside. 8. Remove the rear quarter trim panel.
9. Disconnect the electrical connectors, if necessary.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair
Door Lock Cylinder: Service and Repair
DOOR LOCK CYLINDER
Removal and Installation
NOTE:
- When any new lock cylinder is installed, the driver door and ignition lock cylinders should be
installed as a set. This eliminates carrying an extra key which fits only 1 lock. If a new key is used,
the new key code number is stamped on a metal tag attached to the key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. Remove the front door trim panel. 2. Position the watershield aside. 3. Release the front door
push button rod from the door frame retainer. 4. Remove the exterior front door handle nut (rear).
- To install, tighten to 9 Nm (80 lb-in).
5. Remove the door lock cylinder.
- Disconnect the front door lock cylinder actuating rod.
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 8623
C500
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 8624
Keyless Entry Key-Pad: Testing and Inspection
KEYLESS ENTRY KEYPAD CODE PROGRAMMING
NOTE: A maximum of 3 personal entry codes can be programmed into the vehicle. The personal
entry codes can be associated with up to two memory seat/adjustable pedal settings.
1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds
to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation
erases all
the stored customer codes. The existing codes do not need to be erased to program a new code.
3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. 4. Press the 1/2, 3/4, or 5/6
to indicate which of the three personal entry code positions is to be programmed. 5. The door locks
lock and unlock to confirm the new code is programmed. 6. To program an additional personal
entry code, REPEAT steps 2 through 4.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Locations > Page 8625
Keyless Entry Key-Pad: Service and Repair
KEYLESS ENTRY KEYPAD
Removal and Installation
1. Position the front window glass to the full down position. 2. Position the door glass top run aside
to access the door pillar trim panel screws. 3. Remove the 3 door pillar trim panel screws and the
door pillar trim panel. 4. Disconnect the electrical connector and remove the keyless entry keypad
from the door pillar trim panel. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry Transmitter Programming
Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry Transmitter Programming
REMOTE KEYLESS ENTRY TRANSMITTER PROGRAMMING
NOTE:
- All remote keyless entry (RKE) transmitters must be programmed at the same time.
- Programming of the RKE transmitters can be accomplished using a scan tool or by carrying out
the following steps:
1. The vehicle must be electronically unlocked before entering program mode using the RKE
transmitter, keyless entry keypad (if equipped) or door
lock control switch while the driver door is open.
2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If
the module successfully enters the program
mode, it locks and then unlocks all doors.
3. Within 20 seconds, press any button on an RKE transmitter, and the doors lock and then unlock
to confirm that each RKE transmitter is
programmed. Repeat this step for each RKE transmitter.
4. If the door locks do not respond for any RKE transmitter, wait several seconds and press the
button again. If the door locks still fail to respond,
refer to Inspection and Verification. Make sure that no more than the maximum number of 6 RKE
transmitters are attempted to be programmed. See: Power Locks/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Inspection and Verification
5. Exiting the programming mode is accomplished if one of the following occurs:
- The key transitions to the OFF position.
Twenty seconds have passed since entering programming mode or since the last RKE transmitter
was programmed.
- The maximum number of 6 RKE transmitters have been programmed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry Transmitter Programming > Page 8630
Keyless Entry Transmitter: Testing and Inspection Autolock and Horn Chirp Programming
AUTOLOCK AND HORN CHIRP PROGRAMMING
Autolock Programming Using the Keyless Entry Keypad
1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit
permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code,
press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and
while holding the 3/4 button, press the 7/8 button on the keyless entry keypad and release it.
6. NOTE: If the autolock is disabled, the horn chirps once. If the autolock feature is enabled, the
horn chirps once shortly and then sounds a second
time with a longer sound of the horn once the above sequence is completed.
Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad.
Autolock Programming Using the Ignition Lock Cylinder
1. Close all doors and windows. 2. Confirm that the ignition key is OFF.
3. NOTE: Steps 5 through 9 must be carried out within 30 seconds.
Turn the ignition key from OFF to RUN.
4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to
OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from
OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to
accept program changes. 9. Press the door lock control switch UNLOCK button then the LOCK
button 1 time to command the module to toggle the autolock/relock feature.
10. Verify that the horn chirps. There should be 1 chirp indicating that autolock/relock feature has
been disabled. If 1 chirp is heard, followed by a
longer sound of the horn, the autolock/relock feature has just been enabled.
11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify
that the horn chirps once to indicate that a feature has been changed and that autolock/relock has
been toggled.
Auto-Unlock Programming Using the Keyless Entry Keypad
1. Close all doors and windows. 2. Confirm that the ignition key is OFF. 3. Enter the 5-digit
permanent entry code into the keyless entry keypad. 4. Within 5 seconds of entering the code,
press and hold the 3/4 button on the keyless entry keypad. 5. Within 5 seconds of Step 3, and
while holding the 3/4 button, press the 7/8 button twice on the keyless entry keypad and release it.
6. NOTE: If the auto-unlock is disabled, the horn chirps once. If the auto-unlock feature is enabled,
the horn chirps twice.
Within 5 seconds of Step 3, release the 3/4 button on the keyless entry keypad.
Auto-Unlock Programming Using the Ignition Lock Cylinder
1. Close all doors and windows. 2. Confirm that the ignition key is OFF.
3. NOTE: Steps 5 through 9 must be carried out within 30 seconds.
Turn the ignition key from OFF to RUN.
4. Press the door lock control switch UNLOCK button 3 times. 5. Turn the ignition key from RUN to
OFF. 6. Press the door lock control switch UNLOCK button 3 times. 7. Turn the ignition key from
OFF to RUN. 8. Verify the horn chirps. This indicates the enable/disable mode and now is ready to
accept program changes. 9. Press the door lock control switch LOCK button then the UNLOCK
button 1 time to command the module to toggle the auto-unlock feature.
10. Verify that the horn chirps. There should be 1 chirp indicating that auto-unlock feature has been
disabled. If 1 chirp is heard, followed by a longer
sound of the horn, the auto-unlock feature has just been enabled.
11. Turn the key to the OFF position or wait 2 minutes to exit the enable/disable mode. 12. Verify
that the horn chirps once to indicate that a feature has been changed and that auto-unlock has
been toggled.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Service and Repair > Procedures
Keyless Entry Transmitter: Procedures
Remote Memory Activation
REMOTE MEMORY ACTIVATION
1. Position the driver seat and adjustable pedals to the desired position. 2. Press the set button on
the lower center of the instrument panel. 3. Within 5 seconds press one control on the remote
keyless entry (RKE) transmitter and then the 1 or 2 button on the lower center of the instrument
panel to associate the RKE transmitter to the driver 1 or the driver 2 position. This stores the
configuration for driver 1 or driver 2.
4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter.
Remote Memory Deactivation
REMOTE MEMORY DEACTIVATION
1. Press the set button on the lower center of the instrument panel. 2. Within 5 seconds press one
control on the remote keyless entry (RKE) transmitter and then the set button on the lower center
of the instrument
panel to associate the RKE transmitter to the driver 1 or the driver 2 position.
3. If a second memory setting is desired to be deactivated, repeat the procedure with the second
RKE transmitter.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Service and Repair > Procedures > Page 8633
Keyless Entry Transmitter: Removal and Replacement
TAILGATE LATCH REMOTE CONTROL
Removal and Installation
1. Open and support the tailgate. 2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate
access panel.
- To install, tighten to 5 Nm (44 lb-in).
3. Open the 2 clips and release the 2 tailgate latch actuating rods from the tailgate remote control.
4. Release the 2 tailgate latch actuating rod locators from the tailgate. 5. Remove the 2 nuts and
the tailgate remote control.
- To install, tighten to 9 Nm (80 lb-in).
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side > Page 8639
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side > Page 8640
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Driver Side > Page 8641
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Driver Side
C525
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Driver Side > Page 8644
C603
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Driver Side > Page 8645
C704
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Diagrams > Door Lock Actuator, Driver Side > Page 8646
C804
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator
Power Door Lock Actuator: Service and Repair Front Door Lock Actuator
FRONT DOOR LOCK ACTUATOR
Removal and Installation
1. Remove the front door latch. 2. Disconnect the front door ajar switch and the front door lock
actuator electrical connectors. 3. Release the locking tab and remove the front door lock actuator.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Lock Actuator > Page 8649
Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator
REAR DOOR LOCK ACTUATOR
Removal and Installation
1. Remove the rear door latch. 2. Release the locking tab and remove the rear door lock actuator.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Door Lock Switch, Passenger Side
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Locations > Door Lock Switch, Passenger Side > Page 8654
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Door Lock Switch, Driver Side
C505
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Door Lock Switch, Driver Side > Page 8657
C605
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 8658
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 8659
Power Door Lock Switch: Service and Repair
DOOR LOCK CONTROL SWITCH
Removal and Installation
NOTE: The LH side is shown, the RH side is similar.
1. Remove the interior door handle cover. 2. Remove the front door switch bezel.
- Release the 4 retaining tabs.
3. Disconnect the door lock control switch and window control switch electrical connectors. 4.
Remove the door lock control switch.
- Release the 4 retaining tabs.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Page 8660
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service
and Repair
Trunk / Liftgate Lock Cylinder: Service and Repair
TAILGATE LOCK CYLINDER
Removal and Installation
NOTE:
- When a new lock cylinder is installed, the tailgate lock cylinder, door lock cylinders and the
ignition lock cylinder should be installed as a set. This eliminates carrying an extra key which fits
only 1 lock. If a new key is to be used, the new key code is attached to a tag.
- The individual door lock cylinders are 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 a new lock cylinder to the current key code of the
vehicle.
1. Remove the tailgate release handle. 2. Remove retaining clip and the tailgate lock cylinder. 3. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module >
Component Information > Description and Operation
Memory Positioning Module: Description and Operation
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Belt Tower Position Sensor >
Component Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair
Power Mirror Motor: Service and Repair
EXTERIOR MIRROR MOTOR
Exploded View
Removal and Installation
NOTE: RH shown, LH similar.
1. Remove the exterior mirror glass. 2. Remove the exterior mirror motor screws.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair
> Page 8675
3. Disconnect the exterior mirror motor electrical connectors. 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
8679
C527
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
8680
Power Mirror Switch: Testing and Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
8681
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
8682
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
Removal and Installation
1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front
door trim panel. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes
Paint: Application and ID Paint Codes
PAINT CODES
Vehicle Certification Label
Exterior Paint Code
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 8688
Exterior Paint
Exterior paint codes may be listed as a 2-part code. The first set of characters identify the primary
body color. The second set of characters (if applicable) identify the vehicle accent or 2-tone body
color. All colors are base coat/clear coat.
Primary Exterior Color Codes DX - Dark Blue Pearl - Explorer/Explorer Sport Trac
- G2 - Redfire - Explorer/Mountaineer/Explorer Sport Trac
- G3 - Pueblo Gold - Explorer/Mountaineer/Explorer Sport Trac
- G5 - Alloy Gray - Explorer/Mountaineer/Explorer Sport Trac
- HH - Dark Cherry - Explorer/Mountaineer/Explorer Sport Trac
- JP - Silver Birch Metallic - Explorer/Mountaineer/Explorer Sport Trac
- NL - Orange Frost - Explorer/Explorer Sport Trac
- PV - White Chocolate (tri-coat) - Explorer/Mountaineer
- T7 - Dark Stone - Explorer/Mountaineer/Explorer Sport Trac
- TK - Mineral Gray Metallic - Explorer Sport Trac
- UA - Ebony - Explorer/Mountaineer/Explorer Sport Trac
- YZ - Oxford White - Explorer/Mountaineer/Explorer Sport Trac
Exterior Accent Color Codes G3 - Pueblo Gold - Explorer
Interior Trim
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 8689
Interior Trim
Interior trim codes are Listed as a 2-part code. The first character identifies the interior trim type.
The second character identifies the interior trim color.
Interior Trim Type 3 - Imola perforated leather seats - Mountaineer
- 4 - Imola perforated Leather with heated driver seat - Mountaineer
- 8 - Embossed Leather with preferred suede insert seats - Mountaineer
- I - Imola/Milled Pebble Leather with power, heated driver and passenger seats - Explorer
- R - Treads cloth seats - Explorer/Explorer Sport Trac
- S - Treads cloth with power driver seat - Explorer/Mountaineer/Explorer Sport Trac
- T - Imola/Milled Pebble Leather with power, heated driver seat and memory - Explorer/Explorer
Sport Trac
- V - Imola/Milled Pebble Leather with power driver seat - Explorer
- W - Leather trim with Preferred smooth suede inserts and power driver seat - Explorer
- X - Leather trim with Preferred smooth suede inserts and power/heated/memory driver seat Explorer
- Z - Imola/Milled Pebble Leather with power/heated/memory driver seat - Explorer
Interior Trim Color C - Camel - Explorer/Mountaineer/Explorer Sport Trac
- L - Medium Light Stone - Explorer/Mountaineer/Explorer Sport Trac
- W - Charcoal Black - Explorer/Mountaineer/Explorer Sport
Tape/Paint Stripe
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 8690
Tape/Paint Stripe
Tape and paint stripe codes do not apply.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 8691
Paint: Application and ID Paint Code Sticker Location
PAINT CODE STICKER LOCATION
Vehicle Certification (VC) Label Locator
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module >
Component Information > Description and Operation
Memory Positioning Module: Description and Operation
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Module >
Component Information > Description and Operation
Pedal Positioning Module: Description and Operation
Adjustable Pedals Using the adjustable pedal switch located on the instrument panel, the driver
can adjust the brake and accelerator pedals for a more comfortable driving position. For removal
and installation of the adjustable pedals, refer to Brake Pedal and Bracket.
Adjustable Pedal Operation The adjustable pedals with or without memory feature are operational
with the ignition switch in the ON or OFF position. The pedals are adjusted forward or rearward
using the adjustable pedal switch.
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board
Module > Component Information > Service and Repair
Auxiliary Step / Running Board Module: Service and Repair
RETRACTABLE RUNNING BOARD MODULE
Removal and Installation
1. Remove the RH C-pillar trim panel. 2. Disconnect the retractable running board module electrical
connectors. 3. Remove the 3 screws and the retractable running board module assembly.
- To install, tighten to 7 Nm (62 lb-in).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module >
Component Information > Locations > Page 8705
C921
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component
Information > Locations > Page 8709
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Limit Switch > Component Information > Service and Repair
Sunroof / Moonroof Limit Switch: Service and Repair
ROOF OPENING PANEL CONTROL SWITCH
Removal and Installation
1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors.
3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
ROOF OPENING PANEL MOTOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Service and Repair > Page 8718
Part 2
Exploded Views
Removal and Installation
CAUTION: The roof opening panel motor contains ceramic magnets that may fail at any time if
cracked. Any roof opening panel motor that has been dropped onto a hard surface during removal
or installation should be replaced with a new motor.
NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of
the roof opening panel system, including: whenever the roof opening panel motor has been
removed from the roof opening panel system, the roof opening panel glass has been removed from
the roof opening panel system, the roof opening panel assembly has been removed from the
vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has
been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening
Panel Motor Initialization. See: Service and Repair/Procedures/Roof Opening Panel Motor
Initialization
1. NOTE: Make sure that the roof opening panel glass is in the CLOSED position before removal.
Remove the overhead console.
2. Disconnect the roof opening panel electrical connectors.
3. Remove the 3 roof opening panel motor screws.
- To install, tighten to 3 Nm (27 lb-in).
4. NOTE:
- When installing the roof opening panel motor, it may be necessary to turn the roof opening panel
motor slightly to engage the drive splines.
- Anytime a roof opening panel motor is removed, the cables/mechanisms can experience free-play
movement. It is important that the cables/mechanisms do not move. They are timed to be parallel
with each other.
Remove the roof opening panel motor.
5. To install, reverse the removal procedure.
- Initialize the roof opening panel motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Locations > Page 8722
Sunroof / Moonroof Switch: Diagrams
C912
C9001
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
AIR DEFLECTOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Page 8726
Part 2
Exploded Views
Removal and Installation
1. Move roof opening panel to full OPEN position.
2. Remove the air deflector.
- Remove the 4 screws. To install, tighten to 1 Nm (9 lb-in).
- Remove the air deflector from the roof opening panel frame.
3. To install, reverse the removal procedure.
- Initialize the roof opening panel motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair
Sunroof / Moonroof Frame: Service and Repair
ROOF OPENING PANEL FRAME
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Page 8730
Part 2
Exploded Views
Removal and Installation
NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of
the roof opening panel system, including: whenever the roof opening panel motor has been
removed from the roof opening panel system, the roof opening panel glass has been removed from
the roof opening panel system, the roof opening panel assembly has been removed from the
vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has
been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening
Panel Motor Initialization. See: Service and Repair/Procedures/Roof Opening Panel Motor
Initialization
1. Remove the headliner.
2. Remove the 2 retaining screws and the upper console bracket.
3. Disconnect the roof opening panel motor electrical connector. 4. Disconnect the 4 roof opening
panel drain hoses from the corners of the roof opening panel frame.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair > Page 8731
5. Remove the entertainment center support bracket (if equipped).
- Remove the 7 bolts.
- Remove the support bracket.
CAUTION: To avoid damage to the roof opening panel frame, be sure to support the roof opening
panel frame when removing the frame bolts.
6. Remove the 10 roof opening panel frame bolts.
- To install, tighten to 6 Nm (53 lb-in).
7. Remove the roof opening panel frame. 8. To install, reverse the removal procedure.
- Initialize the roof opening panel motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Module > Component Information > Locations > Page 8735
C921
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Glass
ROOF OPENING PANEL GLASS
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8740
Part 2
Exploded Views
Removal and Installation
NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of
the roof opening panel system, including: whenever the roof opening panel motor has been
removed from the roof opening panel system, the roof opening panel glass has been removed from
the roof opening panel system, the roof opening panel assembly has been removed from the
vehicle, a new roof opening panel motor has been installed, a new roof opening panel glass has
been installed or a new roof opening panel assembly has been installed. Refer to Roof Opening
Panel Motor Initialization. See: Service and Repair/Procedures/Roof Opening Panel Motor
Initialization
1. Open the roof opening panel to the VENT position.
2. Remove the 4 roof opening panel glass screws.
- To install, tighten to 4 Nm (35 lb-in).
3. From the outside of the vehicle, remove the roof opening panel glass assembly. 4. To install,
reverse the removal procedure.
- If installing a new roof opening panel glass seal, use care around the corners to make sure of a
correct seal to the roof opening panel glass.
- Check for correct alignment of the roof opening panel.
- Initialize the roof opening panel motor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8741
Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield
ROOF OPENING PANEL SHIELD
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8742
Part 2
Exploded Views
Removal and Installation
1. Remove the roof opening panel glass. 2. Remove the trough.
- Pull the trough assembly arms outward to release the trough assembly guide arm pins from the
roof opening panel frame to remove.
3. Remove the air deflector.
- Remove the 4 screws. To install, tighten to 1 Nm (9 lb-in).
- Remove the air deflector.
4. Slide the roof opening panel shield forward halfway.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel Glass > Page 8743
5. Disengage the roof opening panel shield guide feet.
1. Push the roof opening panel shield toward one side of the vehicle. 2. Lift the front portion of the
roof opening panel shield upward to disengage the guide feet.
6. Slide the roof opening panel shield forward and release the rear guide feet.
7. NOTE: The roof opening panel shield guide feet can be serviced separately from the roof
opening panel shield.
If necessary, new roof opening panel shield guide feet may be installed at this time.
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module >
Component Information > Description and Operation
Memory Positioning Module: Description and Operation
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Driver Seat Module (DSM) The DSM controls the memory adjustable pedals.
The DSM constantly monitors the systems under its control and records concerns in the form of
diagnostic trouble codes (DTCs). A DTC can be retrieved with the scan tool through the data link
connector (DLC).
Memory Adjustable Pedal Operation The adjustable pedals with memory feature is controlled by
using the memory switches or the remote keyless entry (RKE) transmitter. The exterior mirror and
power driver seat positions are also stored and recalled with the power adjustable pedal positions.
The system can store 3 memory settings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Belt Tower Position Sensor >
Component Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power
Seat Motor
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Power
Seat Motor > Page 8756
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor
C3187
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver
Seat Recliner Motor > Page 8759
C353
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor
Power Seat Motor: Service and Repair Seat Recliner Motor
SEAT RECLINER MOTOR
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8762
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8763
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8764
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8765
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8766
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8767
Passenger Seat Cushion (Part 2)
Exploded View
Removal
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle
and when handling an airbag module. This will reduce the risk of injury in the event of an accidental
deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
front seat backrest. 3. Remove the plastic rivets attaching the backrest trim cover to the inboard
and outboard recliners.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8768
4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the
first row of hog rings.
5. Remove the one-way push clip on the side of the inboard power recliner. Slide the recliner shaft
out from the outboard side of the seat enough to
clear the inboard recliner and power recline motor.
6. Disconnect the electrical connector, remove the screw and the power recline motor.
Installation
1. NOTE: The recliners are synchronized. Do not rotate the recliner shaft until completely installed.
Install the recliner motor.
1. Position the recliner shaft through the recliner motor and inboard recliner. 2. Install a new
one-way push clip onto the recliner shaft at the inboard power recliner. 3. Turn the recliner motor
so the recliner motor mounting hole lines up with the screw hole in the inboard power recliner. 4.
Install the recliner motor bolt. 5. Connect the recliner motor electrical connector.
2. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim
cover lower J-clip. 3. Position the backrest trim cover to the inboard and outboard recliners and
install the plastic rivets. 4. Install the front seat backrest. 5. Install the front seat and repower the
SRS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair >
Seat Recliner Motor > Page 8769
Power Seat Motor: Service and Repair Power-Fold Seat Motor - Third Row
POWER-FOLD SEAT MOTOR - THIRD ROW
Removal and Installation
NOTE: The power-fold seat motor is serviced with the latch bracket.
LH or RH motors
1. Position the backrest with the working motor in the opposite position of the backrest with the
motor that is not working. 2. Remove the third row seat from the vehicle. 3. Remove 2 latch-to-floor
mounting bracket nuts.
- To install, tighten to 22 Nm (16 lb-ft).
LH motor
4. From under the RH seat, remove the 2 cushion pivot link assembly-to-cushion frame nuts and
remove the RH 50 percent seat from the floor
mounting bracket. To install, tighten to 22 Nm (16 lb-ft).
Motor being serviced
5. Remove the latch-to-cushion frame bolt.
- To install, tighten to 25 Nm (18 lb-ft).
6. Remove 2 bolts and the latch cover. 7. Release the backrest trim cover lower J-clip on the side
with the motor being serviced.
8. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover side J-clips, hook-and-loop strips and invert the trim cover to
expose the 2 latch-to-backrest frame bolts on the side with the motor being serviced.
9. Remove the 2 latch-to-backrest frame bolts and remove the latch with motor.
- To install, tighten to 25 Nm (18 lb-ft).
LH motor
10. Remove the safety belt buckle assembly-to-latch nut and remove the safety belt buckle
assembly.
- To install, tighten to 75 Nm (55 lb-ft).
LH or RH motors
11. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page
8773
Power Seat Switch: Diagrams
C352
C3016
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 8776
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Page 8777
Power Seat Switch: Service and Repair
MEMORY SET SWITCH
Removal and Installation
1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center
console door, remove the 2 screws and pull up on the console finish panel to release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out
to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6.
Pull out to release the retainers and separate the instrument panel center finish panel. 7.
Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative
Seat Back: Customer Interest Interior - Front Seat Manual Lumbar Inoperative
TSB 07-7-3
04/16/07
FRONT SEAT MANUAL LUMBAR INOPERATIVE
FORD: 2006-2007 Fusion, Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Milan
This article supersedes TSB 06-21-6 and 06-20-11 to update the Service Procedure and Parts.
ISSUE Some 2006-2007 Fusion and Milan vehicles built prior to 9/4/2006, Explorer
4dr/Mountaineer and 2007 Explorer Sport Trac vehicles built prior to 8/24/2006 may exhibit an
inoperative adjustment of the manual lumbar assembly.
ACTION Follow the service procedure outlined below to address the customer concern.
SERVICE PROCEDURE
Replace the lumbar strap following the lumbar procedure in the Workshop Manual (WSM), Section
501-10. DO NOT remove the cable from the lumbar adjuster. New service parts have been
released and the cables should be disconnected and reconnected at the lumbar strap.
Strap Replacement Procedure:
1. Release the two (2) lumbar spring clips from the backrest frame and remove the lumbar. Refer to
WSM, Section 501-10 for more details.
2. Cut strap to allow removal of the cable in six (6) places while being careful not to damage the
cable. (Figure 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8786
3. Insert cable through zip tie loops and through the two (2) cable guides on the new lumbar strap.
Ensure that the cable is held by the two (2) hooks. (Figure 2)
4. Snap the cable end and cable conduit end into strap. (Figure 3) Verify that both fittings are
properly inserted by pushing on the fittings with the flat sur[ace of a standard screwdriver. After
completing this, make sure that tabs are adequately engaged by pulling them back over the fitting
with a scratch awl or small screwdriver.
NOTE
ON FUSION AND MILAN VEHICLES, THE CABLE DIE CAST MUST BE SNAPPED INTO THE
STRAP NEAR THE BLUE ATTACHMENT WIRE AND THE OUTER CONDUIT END MUST BE
SNAPPED IN TO THE STRAP NEAR THE BLACK CURVED ATTACHMENT WIRE.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8787
5. Zip ties on both the die cast end fitting and conduit end fitting can now be pulled tight and the
excess slack can be cut off. (Figures 4 and 5)
6. To install the lumbar strap assembly, reverse the removal procedure.
NOTE
THE LUMBAR ATTACHMENT WIRES MUST BE RUN IN AND BACK OUT OF THE LANCE TABS
ON THE BACK FRAME. (Figure 6)
7. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove
out the SRS at this time. For additional information, refer to WSM, Section 501-10.
8. On Explorer and Explorer Sport Trac vehicles carry out the Occupant Classification Sensor
(OCS) System Zero Weight Test and prove out the (SRS). Refer to WSM, Section 501-20B
General Procedures.
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
070703A 2006-2007 Fusion/Milan 1.5 Hrs.
With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower
The Supplemental
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
Customer Interest for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page 8788
Restraints System, Remove And Install Seat, Seat Back (Do Not Use With 64416A, 14696A,
14696B, 62900A, 63222A)
070703B 2006-2007 Explorer, 2007 1.5 Hrs.
Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To
Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat
Back: Driver Seat (Do Not Use With 64416A 14696A, 14696B, 62900A, 63222A)
070703C 2006-2007 Explorer, 2007 1.6 Hrs.
Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To
Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat
Back: Passenger Seat (Do Not Use With 64416A, 14696A, 14696B, 62900A, 63222A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7865500 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative
Seat Back: All Technical Service Bulletins Interior - Front Seat Manual Lumbar Inoperative
TSB 07-7-3
04/16/07
FRONT SEAT MANUAL LUMBAR INOPERATIVE
FORD: 2006-2007 Fusion, Explorer 2007 Explorer Sport Trac
MERCURY: 2006-2007 Milan
This article supersedes TSB 06-21-6 and 06-20-11 to update the Service Procedure and Parts.
ISSUE Some 2006-2007 Fusion and Milan vehicles built prior to 9/4/2006, Explorer
4dr/Mountaineer and 2007 Explorer Sport Trac vehicles built prior to 8/24/2006 may exhibit an
inoperative adjustment of the manual lumbar assembly.
ACTION Follow the service procedure outlined below to address the customer concern.
SERVICE PROCEDURE
Replace the lumbar strap following the lumbar procedure in the Workshop Manual (WSM), Section
501-10. DO NOT remove the cable from the lumbar adjuster. New service parts have been
released and the cables should be disconnected and reconnected at the lumbar strap.
Strap Replacement Procedure:
1. Release the two (2) lumbar spring clips from the backrest frame and remove the lumbar. Refer to
WSM, Section 501-10 for more details.
2. Cut strap to allow removal of the cable in six (6) places while being careful not to damage the
cable. (Figure 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page
8794
3. Insert cable through zip tie loops and through the two (2) cable guides on the new lumbar strap.
Ensure that the cable is held by the two (2) hooks. (Figure 2)
4. Snap the cable end and cable conduit end into strap. (Figure 3) Verify that both fittings are
properly inserted by pushing on the fittings with the flat sur[ace of a standard screwdriver. After
completing this, make sure that tabs are adequately engaged by pulling them back over the fitting
with a scratch awl or small screwdriver.
NOTE
ON FUSION AND MILAN VEHICLES, THE CABLE DIE CAST MUST BE SNAPPED INTO THE
STRAP NEAR THE BLUE ATTACHMENT WIRE AND THE OUTER CONDUIT END MUST BE
SNAPPED IN TO THE STRAP NEAR THE BLACK CURVED ATTACHMENT WIRE.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page
8795
5. Zip ties on both the die cast end fitting and conduit end fitting can now be pulled tight and the
excess slack can be cut off. (Figures 4 and 5)
6. To install the lumbar strap assembly, reverse the removal procedure.
NOTE
THE LUMBAR ATTACHMENT WIRES MUST BE RUN IN AND BACK OUT OF THE LANCE TABS
ON THE BACK FRAME. (Figure 6)
7. Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove
out the SRS at this time. For additional information, refer to WSM, Section 501-10.
8. On Explorer and Explorer Sport Trac vehicles carry out the Occupant Classification Sensor
(OCS) System Zero Weight Test and prove out the (SRS). Refer to WSM, Section 501-20B
General Procedures.
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
070703A 2006-2007 Fusion/Milan 1.5 Hrs.
With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To Depower And Repower
The Supplemental
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Seat Back: > 07-7-3 > Apr > 07 > Interior - Front Seat Manual Lumbar Inoperative > Page
8796
Restraints System, Remove And Install Seat, Seat Back (Do Not Use With 64416A, 14696A,
14696B, 62900A, 63222A)
070703B 2006-2007 Explorer, 2007 1.5 Hrs.
Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To
Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat
Back: Driver Seat (Do Not Use With 64416A 14696A, 14696B, 62900A, 63222A)
070703C 2006-2007 Explorer, 2007 1.6 Hrs.
Explorer Sport Trac With Manual Lumbar Seat: Replace The Lumbar Strap, Includes Time To
Depower And Repower The Supplemental Restraints System, Remove And Install Seat, Seat
Back: Passenger Seat (Do Not Use With 64416A, 14696A, 14696B, 62900A, 63222A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7865500 01
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement
Seat Back: Removal and Replacement
Seat Backrest - Front
SEAT BACKREST - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8799
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8800
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8801
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8802
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8803
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8804
Passenger Seat Cushion (Part 2)
Exploded View
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Driver seat shown, passenger seat similar.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8805
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
cushion side shield.
1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the
manual lumbar control knob.
- Make sure the lumbar is completely relaxed before removing the handle.
3. Remove the scrivet. 4. Release the cushion side shield front clip. 5. From under the cushion side
shield, release the 3 hook retainers. 6. Pull out on the cushion side shield at the back and release
the pin-type retainer. 7. Separate the cushion trim cover elastic strap from the cushion side shield.
- If equipped with a manual seat track, remove the cushion side shield.
8. If equipped with power seats, remove the seat control switch knob and separate the seat control
switch from the cushion side shield.
- Remove the cushion side shield.
3. Release the cushion trim cover rear J-clips.
1. Release the cushion trim cover rear inboard J-clip from the inboard recliner. 2. For a driver seat
or passenger seat equipped with heat, release the cushion trim cover rear J-clips.
4. Release the cushion trim cover inboard J-clip. 5. Remove the safety belt buckle and pretensioner
electrical connector cover. 6. Remove the 2 safety belt buckle and pretensioner nuts.
- To install, tighten to 36 Nm (27 lb-ft).
7. Disconnect the safety belt buckle and pretensioner electrical connector and safety belt buckle
switch electrical connector.
- Remove the safety belt buckle and pretensioner.
Seat with manual lumbar
8. Release the cushion trim cover front J-clip. Raise the cushion foam pad and release the lumbar
cable pin-type retainer. 9. Remove the 2 screws and separate the manual lumbar control from the
cushion frame.
10. Remove the cable from the manual lumbar control.
Driver seat with power recline
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8806
11. Disconnect the backrest power feed electrical connector and route out the wire harness.
- Release any wire harness retainers.
Passenger seat with heat
12. Disconnect the backrest heated seat mat electrical connector and route out the wire harness.
- Release any wire harness retainers.
All seats
13. Release the pin-type retainers, disconnect and route out the side air bag module electrical
connector and wire harness.
14. NOTE: Driver seat shown, passenger seat similar.
Release the side air bag wire harness pin-type retainers across the back of the cushion frame.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8807
15. Remove the 4 recliner-to-cushion frame bolts and remove the backrest assembly.
- Route out the manual lumbar cable and any wire harnesses (if equipped).
- To install, tighten to 55 Nm (41 lb-ft).
16. To install, reverse the removal procedure. 17. Install the front seat and repower the SRS. If a
passenger seat has been serviced, do not prove out the SRS at this time.
Passenger seat
18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Seat Backrest - Second Row, 40 Percent E-Z Entry
SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8808
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8809
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8810
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8811
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8812
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8813
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8814
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8815
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8816
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8817
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8818
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8819
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8820
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8821
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal
1. Remove the second row, 40 percent E-Z entry seat from the vehicle.
2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest
trim cover to expose the 2 inboard and 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8822
outboard recliner-to-backrest frame bolts.
3. Separate the kneeling mechanism release handle from the backrest frame.
- Release the 3 kneeling mechanism release handle clips and separate from the backrest frame.
Pull the kneeling mechanism release handle and cable back through the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by
going between the backrest foam pad and backrest frame. Release the top and side clips and push
out separating the kneeling mechanism release handle from the backrest frame.
4. Release the kneeling mechanism cable from the backrest frame. 5. Remove the 2 inboard and 2
outboard recliner-to-backrest frame bolts and remove the backrest assembly.
Installation
1. Remove 3 screws, recliner handle and outboard recliner outer cover. 2. Remove 2 screws and
the inboard recliner outer cover.
3. WARNING: The recliner(s) are spring-loaded. Use care when seat back frame is removed and
releasing the recliners from a backrest
upright position. The recliner upper arms will fold with significant speed/force. Failure to follow this
instruction may result in personal injury.
Position the inboard recliner pin to the recliner stop. The recliner pin must contact the inboard recliner outer plate (stop).
4. WARNING: The recliner(s) are spring-loaded. Use care when seat back frame is removed and
releasing the recliners from a backrest
upright position. The recliner upper arms will fold with significant speed/force. Failure to follow this
instruction may result in personal injury.
NOTE: If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock
in position.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8823
- If the inboard recliner is not positioned to the recliner stop (or any upright position), when the
outboard recliner is positioned to the recliner stop and the release strap is let go of, the recliners
will not lock in place.
Pull the release strap at the outboard recliner and position the outboard recliner pin to contact the
recliner stop. Let go of the release strap and the inboard and outboard recliners will lock in place. Each recliner pin must contact the recliner outer plate (stop).
5. Position the backrest assembly to the inboard and outboard recliners and hand start the 2
inboard and 2 outboard recliner-to-backrest frame bolts.
6. CAUTION: The recliner-to-backrest frame bolts must be tightened in sequence or recliner
latches that do not lock in place or binding
may occur.
Install the recliner-to-backrest frame bolts in the following sequence: 1. Install the inboard
recliner-to-backrest frame upper bolt.
- Tighten to 55 Nm (41 lb-ft).
2. Install the inboard recliner-to-backrest frame lower bolt.
- Tighten to 55 Nm (41 lb-ft).
3. Install the outboard recliner-to-backrest frame upper bolt.
- Tighten to 55 Nm (41 lb-ft).
4. Install the outboard recliner-to-backrest frame lower bolt.
- Tighten to 55 Nm (41 lb-ft).
7. Position the kneeling mechanism release handle and cable back through the backrest frame and
backrest trim cover openings.
- Attach the kneeling mechanism release cable to the backrest frame.
8. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim
cover lower J-clip. 9. Position the kneeling mechanism release handle to the backrest opening and
push in, engaging the clips.
10. Route the outboard recliner release strap before installing the outboard recliner outer cover. 11.
Install the outboard recliner outer cover.
- Position the outboard recliner outer cover.
- Route the release strap through the cover.
- Install the 2 screws.
- Install the recliner handle.
- Install the screw.
12. Position the inboard recliner outer cover and install the 2 screws. 13. Install the second row, 40
percent E-Z entry seat into the vehicle. 14. Cycle the backrest down and then back to the upright
position. Make sure the inboard and outboard recliners simultaneously and securely lock in
the upright position.
Seat Backrest - Second Row, 60 Percent, E-Z Entry
SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8824
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8825
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8826
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8827
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8828
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8829
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8830
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8831
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8832
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8833
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8834
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8835
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8836
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8837
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal
1. Remove the second row, 60 percent E-Z entry seat from the vehicle.
2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest
trim cover to expose the 2 inboard and 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8838
outboard recliner-to-backrest frame bolts.
3. Separate the kneeling mechanism release handle from the backrest frame.
- Release the 3 kneeling mechanism release handle clips and separate from the backrest frame.
Pull the kneeling mechanism release handle and cable back through the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by
going between the backrest foam pad and backrest frame. Release the top and side clips and push
out separating the kneeling mechanism release handle from the backrest frame.
4. Release the kneeling mechanism cable from the backrest frame. 5. Remove 2 screws and the
inboard recliner outer cover. 6. Remove the safety belt anchor bolt and separate the safety belt
anchor from the inboard recliner. 7. Remove the 2 inboard and 2 outboard recliner-to-backrest
frame bolts and remove the backrest assembly.
Installation
1. Remove 3 screws, recliner handle and outboard recliner outer cover.
2. WARNING: The recliner(s) are spring-loaded. Use care when seat back frame is removed and
releasing the recliners from a backrest
upright position. The recliner upper arms will fold with significant speed/force. Failure to follow this
instruction may result in personal injury.
NOTE: This is a 2 person operation.
- If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock
in position.
- If both of the recliners are not locked in place simultaneously, the recliners will not lock in position.
Simultaneously pull the release strap at the outboard recliner and position the inboard and
outboard recliner pins to the recliner stops. Let go of the release strap and the inboard and
outboard recliners will lock in place.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8839
- Each recliner pin must contact the recliner outer plate (stop).
3. Position the backrest assembly to the inboard and outboard recliners and hand start the 2
inboard and 2 outboard recliner-to-backrest frame bolts.
4. CAUTION: The recliner-to-backrest frame bolts must be tightened in sequence or recliner
latches that do not lock in place or binding
may occur.
Install the recliner-to-backrest frame bolts in the following sequence. 1. Install the inboard
recliner-to-backrest frame upper bolt.
- Tighten to 55 Nm (41 lb-ft).
2. Install the inboard recliner-to-backrest frame lower bolt.
- Tighten to 55 Nm (41 lb-ft).
3. Install the outboard recliner-to-backrest frame upper bolt.
- Tighten to 55 Nm (41 lb-ft).
4. Install the outboard recliner-to-backrest frame lower bolt.
- Tighten to 55 Nm (41 lb-ft).
5. Position the kneeling mechanism release handle and cable back through the backrest frame and
backrest trim cover openings.
- Attach the kneeling mechanism release cable to the backrest frame.
6. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the backrest trim
cover lower J-clip. 7. Position the kneeling mechanism release handle to the backrest opening and
push in, engaging the clips.
8. Route the outboard recliner release strap before installing the outboard recliner outer cover. 9.
Position the outboard recliner outer cover, recliner handle and install the 3 screws.
10. CAUTION: Make sure the safety belt webbing is not twisted prior to installation.
Position the safety belt anchor to the inboard recliner and install the safety belt anchor bolt. Tighten to 55 Nm (41 lb-ft).
11. Position the inboard recliner outer cover and install the 2 screws.
- Make sure the kneeling mechanism release cable pivot is still positioned on the inboard recliner
and the recliner pin is through the cable pivot before installing the inboard recliner outer cover.
12. Install the second row, 60 percent E-Z entry seat into the vehicle. 13. Cycle the backrest down
and then back to the upright position. Make sure the inboard and outboard recliners simultaneously
and securely lock in
the upright position.
Seat Backrest - Second Row, 40 Percent, Bench
SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8840
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8841
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8842
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8843
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8844
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8845
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8846
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8847
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8848
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8849
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8850
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8851
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8852
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8853
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal
1. Release the seat backrest J-clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8854
2. Remove all the staples holding the backrest trim cover to the backrest support panel. 3. Invert
the seat backrest trim cover and foam pad to access the latch cover screws. 4. Remove the 4
screws and the 2 covers. Detach the seat backrest material attachment from both of the latch
covers. 5. Remove the 2 backrest support panel lower screws and detach the latch cable. Position
the cable out from between the backrest frame and backrest
support panel.
6. Remove the 4 backrest pivot bolts. 7. Remove the 40 percent backrest.
Installation
1. Position the backrest to the latch. The cable is to be routed in front of the spring.
2. CAUTION: The cable is to move freely after assembly.
NOTE: When installing the backrest to the cushion, make sure the latch cover does not come in
contact with the latch cable conduit or end fitting.
The cable is to pass between the backrest frame and the backrest support at the 2 points shown.
3. Install the 4 backrest pivot bolts.
- Tighten to 40 Nm (30 lb-ft).
4. Install the 2 backrest support panel lower screws.
5. CAUTION: When installing the backrest to the cushion, make sure the latch cover does not
come in contact with the latch cable conduit
or end fitting.
Position the 2 covers and install the 4 screws. Attach the material attachments to both of the latch
covers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8855
6. Roll the seat backrest trim cover and foam pad back down into position. 7. Position the trim
cover and install staples in the backrest support panel. 8. Attach the seat backrest J-clip.
Seat Backrest - Second Row, 60 Percent, Bench
SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8856
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8857
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8858
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8859
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8860
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8861
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8862
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8863
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8864
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8865
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8866
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8867
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8868
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal
1. Remove the safety belt anchor bolt. 2. Release the seat backrest J-clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8869
3. Remove all the staples holding the backrest trim cover to the backrest support panel. 4. Invert
the seat backrest trim cover and reposition the foam pad to access the latch cover screws and
latch cable. 5. Remove the 4 screws and the 2 covers. Detach the seat backrest material
attachment from both of the latch covers. 6. Remove the 2 backrest support panel lower screws
and detach the latch cable. Position the cable out from between the backrest frame and backrest
support panel.
7. Remove the outboard upper pivot latch bolt. 8. Remove the 4 backrest pivot bolts. 9. Remove
the 60 percent backrest.
Installation
1. Position the backrest to the latch. The cable is to be routed in front of the spring.
2. CAUTION: The cable is to move freely after assembly.
The cable is to pass between the backrest frame and the backrest support at the 2 points shown.
3. Install the 4 backrest pivot bolts.
- Tighten to 40 Nm (30 lb-ft).
4. Install the outboard pivot latch bolt.
- Tighten to 40 Nm (30 lb-ft).
5. Install the 2 backrest support panel lower screws. 6. Attach the material to both of the latch
covers. Position the 2 covers and install the 4 screws. 7. Roll the seat backrest trim cover and foam
pad back down into position. 8. Position the trim cover and install staples in the backrest support
panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8870
9. Attach the seat backrest J-clip.
10. Position the safety belt anchor and install the bolt.
- Tighten to 75 Nm (55 lb-ft).
Seat Backrest - Second Row, Bucket
SEAT BACKREST - SECOND ROW, BUCKET
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8871
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8872
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8873
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8874
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8875
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8876
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8877
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8878
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8879
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8880
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8881
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8882
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8883
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Release all of the seat backrest J-clips. Slightly raise the backrest trim cover. 2. Remove all of
the staples in the backrest trim cover. 3. Pull the seat backrest material up and remove the 4
backrest bolts. Remove the backrest assembly.
- To install, tighten to 23 Nm (17 lb-ft).
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8884
Seat Backrest - Third Row
SEAT BACKREST - THIRD ROW
Third Row Seat Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8885
Third Row Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8886
Third Row Seat Cushion (Part 2)
Exploded View
Removal and Installation
All seats
1. Fold the backrest not being serviced down. 2. Remove 2 bolts and the hinge cover on the
backrest being serviced. 3. Remove 2 bolts and the latch cover on the backrest being serviced. 4.
Release the backrest trim cover lower J-clip on the backrest being serviced.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover side J-clips, hook-and-loop strips and invert the trim cover to
expose the 2 hinge-to-backrest frame bolts and the 2 latch-to-backrest frame bolts on the backrest
being serviced.
Manual fold seats
6. Separate the cable casing from the latch and remove the cable from the latch lever on the
backrest being serviced.
All seats
7. Remove the 2 hinge-to-backrest frame bolts and the 2 latch-to-backrest frame bolts and remove
the backrest.
- To install, tighten to 25 Nm (18 lb-ft).
8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8887
Seat Back: Overhaul
Seat Backrest - Front
SEAT BACKREST - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8888
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8889
Front Seat Backrest (Part 2)
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.
- Carry a live side air bag module with the air bag and tear seam pointed away from your body.
This will reduce the risk of injury in the event of an accidental deployment.
- Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Side air bag modules with damaged covers must be replaced.
- Front seat back trim covers installed on seats equipped with side air bags cannot be repaired,
they are to be replaced. Cleaning is permissible.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a side air bag deployment took place a new backrest foam pad, backrest trim cover and side air
bag module must be installed. A new backrest frame should be installed if necessary.
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the restraint control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The supplemental restraint system (SRS) must be fully operational and free of faults before
releasing the vehicle to the customer.
- The manual recliners and power recliners are serviced as part of the backrest frame.
All seats 1. Remove the front seat and depower the supplemental restraint system (SRS). 2.
Remove the front seat backrest.
3. Remove the head restraint.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8890
1. Using an appropriate tool, push in the hole while lifting up and release the head restraint from
the head restraint guide. 2. Push in on the head restraint guide release tab and remove the head
restraint.
4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the
first row of hog rings.
6. Remove the first row of hog rings.
7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings.
8. NOTE: The head restraint guides are not interchangeable. Note location for installation.
Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the
2 head restraint guides out of the backrest frame.
9. Remove the backrest trim cover.
Heated seat 10. For power driver seat, disconnect the backrest heated seat mat electrical
connector.
- If necessary, remove the backrest heated seat mat from the backrest foam pad.
All seats 11. Separate the backrest foam pad from the backrest frame.
12. NOTE: Note the side air bag module wire harness routing for assembly.
Release the side air bag module wire harness pin-type retainers, remove the bolts and the side air
bag module with wire harness.
Seat with manual lumbar 13. Release the 2 manual lumbar spring clips from the backrest frame
and remove the manual lumbar.
Seat with power lumbar 14. Remove the power lumbar adjust assembly.
1. Disconnect the power lumbar adjust assembly motor electrical connector. 2. Release the 2
power lumbar adjust assembly lower pin-type retainers to the backrest frame. 3. Slide the power
lumbar adjust assembly rods out of the backrest frame at the top and remove the power lumbar
adjust assembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8891
Seat with power recline 15. Remove a one-way push clip from the recliner shaft and remove the
recliner shaft. 16. Disconnect the electrical connector, remove the screw and the power recline
motor.
Assembly
Seat with power recline
1. NOTE: The recliners are synchronized. Do not rotate the recliner shaft until completely installed.
Install the recliner motor. Position the recliner shaft through the inboard power recliner, power recline motor and outboard
recliner. Slight turning of the recliner shaft may be necessary.
- Install a new one-way push clip at each end of the recliner shaft.
- Turn the power recline motor so the mounting hole lines up with the bolt hole in the inboard power
recliner.
- Install the power recline motor bolt.
- Connect the power recline motor electrical connector.
Seat with power lumbar 2. Install the power lumbar adjust assembly.
- Slide the power lumbar adjust assembly rods into the backrest frame holes at the top.
- Attach the 2 power lumbar adjust assembly lower pin-type retainers to the backrest frame.
- Connect the power lumbar adjust assembly motor electrical connector.
Seat with manual lumbar 3. Attach the 2 manual lumbar spring clips to the backrest frame.
All seats
4. WARNING:
- Before installing the side air bag module, check it for damage and foreign objects. If the air bag
module is damaged, install a new one. 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.
- Inspect the mounting surfaces of the side air bag module and the seat back frame 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 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.
CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air
bag module and the mounting bracket.
Align the holes of the side air bag module bracket to the U-nuts on the backrest frame. Install new U-nuts if installing a new side air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8892
5. Slide the side air bag module onto the backrest frame so the bracket hook wraps around the
backrest frame. 6. Install the side air bag module bolts, route the wire harness as noted during
disassembly and install the side air bag module wire harness pin-type
retainers. Tighten to 10 Nm (89 lb-in).
Heated seat 7. If necessary, install the backrest heated seat mat.
- For driver seats with power recline, connect the backrest heated seat mat electrical connector.
All seats 8. Position the backrest foam pad around the backrest frame. 9. Position the backrest trim
cover to the backrest frame and foam pad.
10. Roll the backrest trim cover down, attach the hook-and-loop strips and install the second row of
hog rings.
11. Roll the backrest trim cover down, attach the hook-and-loop strips and install the first row of
hog rings. 12. Roll the backrest trim cover down, attach the hook-and-loop strips and connect the
backrest trim cover lower J-clip. 13. Position the backrest trim cover to the inboard and outboard
recliners and install the plastic rivets.
14. NOTE: The head restraint guides are not interchangeable.
Install the head restraint guides.
15. Install the head restraint. 16. Install the front seat backrest. 17. Install the front seat and
repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this time.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8893
Passenger seat 18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight
Test and prove out the SRS.
Seat Backrest - Second Row, 40 Percent E-Z Entry
SEAT BACKREST - SECOND ROW, 40 PERCENT E-Z ENTRY
Second Row, 40 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8894
Second Row, 40 Percent E-Z Entry Backrest (Part 2)
Disassembly and Assembly
1. Remove the second row, 40 percent E-Z entry seat from the vehicle. 2. Remove the second row,
40 percent E-Z entry seat backrest. 3. Using an appropriate tool, push in the hole of each head
restraint guide while lifting up and remove the head restraint.
4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the hook-and-loop strips, invert the trim cover as high as it will go.
5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together
and remove the 2 head restraint guides. 6. Remove the backrest trim cover. 7. Separate the
backrest foam pad from the backrest frame. 8. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, 60 Percent, E-Z Entry
SEAT BACKREST - SECOND ROW, 60 PERCENT, E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8895
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8896
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Disassembly
1. Remove the second row, 60 percent E-Z entry seat. 2. Remove the second row, 60 percent E-Z
entry seat backrest.
3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint. 4. Remove the safety belt bezel.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the hook-and-loop strips and invert the trim cover as high as it will go.
6. From between the backrest foam pad and the backrest frame, reach up pinch the ends together
and remove the 2 head restraint guides. 7. Route out the safety belt and remove the backrest trim
cover. 8. Remove the backrest foam pad from the backrest frame. 9. Remove the safety belt
retractor cover.
- Remove the pin-type retainer.
- Release the rear of the safety belt retractor cover from the backrest frame.
- Route out the safety belt and remove the safety belt retractor cover.
10. Remove the bolt, safety belt retractor and insulator.
- To install, tighten to 75 Nm (55 lb-ft).
- If necessary, remove the safety belt retractor insulator.
11. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, 40 Percent, Bench
SEAT BACKREST - SECOND ROW, 40 PERCENT, BENCH
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8897
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8898
Disassembly and Assembly
1. Remove the second row, 40 percent seat. 2. Remove the second row, 40 percent seat backrest.
3. Remove the screw and the release handle. 4. Remove the 3 screws and the latch cover. 5.
Remove the bolt and the safety belt buckle.
- To install, tighten to 55 Nm (41 lb-ft).
6. Remove the head restraint.
7. NOTE:
- The inboard and outboard head restraint sleeves are not interchangeable.
- The head restraint sleeves incorporate an alignment tab that must face forward when installed.
Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube.
8. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Separate the hook-and-loop fasteners. Remove the seat backrest trim cover.
9. Remove the backrest foam pad.
10. Remove the 2 outboard lower latch bolts.
- To install, tighten to 40 Nm (30 lb-ft).
11. Remove the 2 inboard lower latch bolts.
- To install, tighten to 40 Nm (30 lb-ft).
12. CAUTION: Do not detach the latch cable from the seat latches. The latch assembly is
synchronized; if disassembled, the latch assembly
may not operate correctly.
Remove the latch assembly. Do not separate or disassemble the latch assembly components.
13. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, 60 Percent, Bench
SEAT BACKREST - SECOND ROW, 60 PERCENT, BENCH
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8899
Disassembly and Assembly
1. Remove the second row, 60 percent seat. 2. Remove the second row, 60 percent seat backrest.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8900
3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
4. NOTE:
- The inboard and outboard head restraint sleeves are not interchangeable.
- The head restraint sleeves incorporate an alignment tab that must face forward when installed.
Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube.
5. Pull at the bottom and remove the safety belt guide cover.
6. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Separate the hook-and-loop fasteners, invert the backrest trim cover and remove the hog rings.
Remove the backrest trim cover. Feed the safety belt out through the backrest trim cover.
7. Remove the backrest foam pad. 8. Remove the safety belt retractor cover. 9. Remove the bolt
and the safety belt retractor.
- To install, tighten to 75 Nm (55 lb-ft).
10. To assemble, reverse the disassembly procedure.
Seat Backrest - Second Row, Bucket
SEAT BACKREST - SECOND ROW, BUCKET
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8901
Disassembly and Assembly
1. Remove the second row, 40 percent bucket seat backrest. 2. Remove the head restraint.
3. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Separate the backrest trim cover hook-and-loop fasteners, remove 2 rows of hog rings and invert
the backrest trim cover as high as it will go.
4. NOTE:
- The inboard and outboard head restraint sleeves are not interchangeable.
- The head restraint sleeves incorporate an alignment tab that must face forward when installed.
Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube.
5. Remove the backrest trim cover. 6. Remove the backrest foam pad from the backrest frame.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8902
7. To assemble, reverse the disassembly procedure.
Seat Backrest - Third Row
SEAT BACKREST - THIRD ROW
Third Row Seat Backrest
Disassembly and Assembly
All seats
1. Remove the seat backrest. 2. Release the backrest trim cover J-clip at the top of the trim cover
by the head restraint.
- Pull the head restraint release strap through the backrest trim cover.
3. Remove the 2 head restraint-to-backrest frame bolts and remove the head restraint.
- To install, tighten to 25 Nm (18 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair >
Removal and Replacement > Page 8903
Manual fold seats
4. Release the 3 backrest release handle clips and separate from the backrest.
All seats
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the hook-and-loop strips, invert and remove the backrest trim cover. If equipped, route the backrest release handle and cable through the backrest trim cover.
Manual fold seats
6. Route the backrest release cable out of the backrest frame and remove the backrest release
handle and cable.
All seats
7. Separate the backrest foam pad from the backrest frame. 8. To assemble, reverse the
disassembly procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front
Seat Cover: Service and Repair Seat Backrest Cover - Front
SEAT BACKREST COVER - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8908
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8909
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8910
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8911
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8912
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8913
Passenger Seat Cushion (Part 2)
Exploded View
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Front seat back trim covers installed on seats equipped with side air bags cannot be repaired;
they are to be replaced (cleaning is permissible).
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8914
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
front seat backrest.
3. Remove the head restraint.
1. Using an appropriate tool, push in the hole while lifting up and release the head restraint from
the head restraint guide. 2. Push in on the head restraint guide release tab and remove the head
restraint.
4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the
first row of hog rings.
6. Remove the first row of hog rings.
7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings.
8. NOTE: The head restraint guides are not interchangeable. Note location for installation.
Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the
2 head restraint guides out of the backrest frame.
9. Remove the backrest trim cover.
10. To install, reverse the removal procedure. 11. Install the front seat backrest. 12. Install the front
seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this
time.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8915
Passenger seat
13. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8916
Seat Cover: Service and Repair Seat Cushion Cover - Front
SEAT CUSHION COVER - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8917
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8918
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8919
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8920
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8921
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8922
Passenger Seat Cushion (Part 2)
Exploded View
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
cushion side shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8923
1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the
manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5.
From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side
shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap
from the cushion side shield.
- If equipped with a manual seat track, remove the cushion side shield.
8 If equipped with power seats, remove the seat control switch knob and separate the seat control
switch from the cushion side shield. Remove the cushion side shield.
3. Release all the cushion trim cover to cushion frame retainers.
4. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the cushion foam pad.
Release the hook-and-loop strips, remove the hog rings and remove the cushion trim cover from
the cushion foam pad.
5. To install, reverse the removal procedure. 6. Install the front seat and repower the SRS. If a
passenger seat has been serviced, do not prove out the SRS at this time.
Passenger seat
7. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8924
Seat Cover: Service and Repair Seat Backrest Cover - Second Row, 40 Percent E-Z Entry
SEAT BACKREST COVER - SECOND ROW, 40 PERCENT E-Z ENTRY
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8925
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8926
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8927
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8928
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8929
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8930
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8931
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8932
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8933
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8934
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8935
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8936
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8937
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8938
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the trim
cover.
3. Separate the kneeling mechanism release handle from the backrest frame.
- Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by
going between the backrest foam pad and backrest frame. Release the top and side clips and push
out, separating the kneeling mechanism release handle from the backrest frame.
4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the hook-and-loop strips and invert the trim cover as high as it will go. Pull the kneeling mechanism release handle and cable through the backrest trim cover opening.
5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together
and remove the head restraint guides. 6. Remove the backrest trim cover. 7. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8939
Seat Cover: Service and Repair Seat Backrest Cover - Second Row, 60 Percent, E-Z Entry
SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8940
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8941
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8942
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8943
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8944
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8945
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8946
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8947
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8948
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8949
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8950
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8951
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8952
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8953
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint. 2. Remove 2 screws and the inboard recliner outer cover.
3. CAUTION: Make sure the safety belt webbing is not twisted prior to installation.
Remove the safety belt anchor bolt and separate safety belt anchor from the inboard recliner. To install, tighten to 55 Nm (41 lb-ft).
4. Remove the safety belt bezel.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest
trim cover.
6. Separate the kneeling mechanism release handle from the backrest frame.
- Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by
going between the backrest foam pad and backrest frame. Release the top and side clips and push
out separating the kneeling mechanism release handle from the backrest frame.
7. Release the hook-and-loop strips and invert the trim cover as high as it will go.
- Pull the kneeling mechanism release handle and cable through the backrest trim cover opening.
8. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together
and remove the 2 head restraint guides. 9. Route out the safety belt and remove the backrest trim
cover.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8954
Seat Cover: Service and Repair
Seat Backrest Cover - Front
SEAT BACKREST COVER - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8955
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8956
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8957
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8958
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8959
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8960
Passenger Seat Cushion (Part 2)
Exploded View
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Front seat back trim covers installed on seats equipped with side air bags cannot be repaired;
they are to be replaced (cleaning is permissible).
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8961
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
front seat backrest.
3. Remove the head restraint.
1. Using an appropriate tool, push in the hole while lifting up and release the head restraint from
the head restraint guide. 2. Push in on the head restraint guide release tab and remove the head
restraint.
4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and invert the trim cover to the
first row of hog rings.
6. Remove the first row of hog rings.
7. Release the hook-and-loop strips, invert the trim cover and remove the second row of hog rings.
8. NOTE: The head restraint guides are not interchangeable. Note location for installation.
Reach up into the backrest and squeeze the head restraint guide ends together to release. Pull the
2 head restraint guides out of the backrest frame.
9. Remove the backrest trim cover.
10. To install, reverse the removal procedure. 11. Install the front seat backrest. 12. Install the front
seat and repower the SRS. If a passenger seat has been serviced, do not prove out the SRS at this
time.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8962
Passenger seat
13. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Seat Cushion Cover - Front
SEAT CUSHION COVER - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8963
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8964
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8965
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8966
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8967
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8968
Passenger Seat Cushion (Part 2)
Exploded View
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
cushion side shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8969
1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the
manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5.
From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side
shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap
from the cushion side shield.
- If equipped with a manual seat track, remove the cushion side shield.
8 If equipped with power seats, remove the seat control switch knob and separate the seat control
switch from the cushion side shield. Remove the cushion side shield.
3. Release all the cushion trim cover to cushion frame retainers.
4. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the cushion foam pad.
Release the hook-and-loop strips, remove the hog rings and remove the cushion trim cover from
the cushion foam pad.
5. To install, reverse the removal procedure. 6. Install the front seat and repower the SRS. If a
passenger seat has been serviced, do not prove out the SRS at this time.
Passenger seat
7. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Seat Backrest Cover - Second Row, 40 Percent E-Z Entry
SEAT BACKREST COVER - SECOND ROW, 40 PERCENT E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8970
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8971
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8972
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8973
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8974
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8975
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8976
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8977
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8978
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8979
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8980
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8981
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8982
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8983
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8984
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint.
2. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the trim
cover.
3. Separate the kneeling mechanism release handle from the backrest frame.
- Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by
going between the backrest foam pad and backrest frame. Release the top and side clips and push
out, separating the kneeling mechanism release handle from the backrest frame.
4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the hook-and-loop strips and invert the trim cover as high as it will go. Pull the kneeling mechanism release handle and cable through the backrest trim cover opening.
5. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together
and remove the head restraint guides. 6. Remove the backrest trim cover. 7. To install, reverse the
removal procedure.
Seat Backrest Cover - Second Row, 60 Percent, E-Z Entry
SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8985
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8986
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8987
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8988
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8989
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8990
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8991
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8992
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8993
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8994
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8995
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8996
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8997
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8998
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 8999
1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint. 2. Remove 2 screws and the inboard recliner outer cover.
3. CAUTION: Make sure the safety belt webbing is not twisted prior to installation.
Remove the safety belt anchor bolt and separate safety belt anchor from the inboard recliner. To install, tighten to 55 Nm (41 lb-ft).
4. Remove the safety belt bezel.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover lower J-clip, hook-and-loop strips and partially invert the backrest
trim cover.
6. Separate the kneeling mechanism release handle from the backrest frame.
- Release the 3 kneeling mechanism release handle clips and separate from the backrest frame. Separating the kneeling mechanism release handle from the backrest frame can also be done by
going between the backrest foam pad and backrest frame. Release the top and side clips and push
out separating the kneeling mechanism release handle from the backrest frame.
7. Release the hook-and-loop strips and invert the trim cover as high as it will go.
- Pull the kneeling mechanism release handle and cable through the backrest trim cover opening.
8. From between the backrest foam pad and the backrest frame, reach up, pinch the ends together
and remove the 2 head restraint guides. 9. Route out the safety belt and remove the backrest trim
cover.
10. To install, reverse the removal procedure.
Seat Cushion Cover - Second Row, 40 Percent E-Z Entry
SEAT CUSHION COVER - SECOND ROW, 40 PERCENT E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9000
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9001
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9002
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9003
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9004
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9005
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9006
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9007
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9008
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9009
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9010
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9011
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9012
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9013
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Remove the 2 screws and the latch feet release bar. 2. Release all the cushion trim cover
retainers and pin-type retainers.
3. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the cushion foam pad.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9014
Release the hook-and-loop strips and remove the cushion trim cover from the cushion foam pad.
4. To install, reverse the removal procedure.
Seat Cushion Cover - Second Row, 60 Percent, E-Z Entry
SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, E-Z ENTRY
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9015
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9016
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9017
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9018
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9019
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9020
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9021
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9022
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9023
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9024
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9025
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9026
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9027
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Remove the 2 screws and the latch feet release bar. 2. Release all the cushion trim cover
retainers and pin-type retainers.
3. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the cushion foam pad.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9028
Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad.
4. To install, reverse the removal procedure.
- After installation, make sure the LATCH and safety belt buckles are accessible to the occupants.
Seat Backrest Cover - Second Row, 40 Percent, Bench
SEAT BACKREST COVER - SECOND ROW, 40 PERCENT, BENCH
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9029
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9030
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9031
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9032
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9033
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9034
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9035
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9036
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9037
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9038
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9039
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9040
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9041
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Remove the head restraint. 2. Release the seat backrest J-clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9042
3. Remove all the staples holding the backrest trim cover to the backrest support panel. 4. Invert
the seat backrest trim cover and foam pad to access the head restraint sleeve.
5. NOTE:
- The inboard and outboard head restraint sleeves are not interchangeable.
- The head restraint sleeves incorporate an alignment tab that must face forward when installed.
Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube.
6. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
seat backrest foam pad.
Separate the hook-and-loop fasteners. Remove the seat backrest trim cover.
7. To install, reverse the removal procedure.
Seat Backrest Cover - Second Row, 60 Percent, Bench
SEAT BACKREST COVER - SECOND ROW, 60 PERCENT, BENCH
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9043
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9044
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9045
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9046
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9047
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9048
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9049
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9050
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9051
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9052
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9053
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9054
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9055
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9056
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Remove the second row, 60 percent seat.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9057
2. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and
remove the head restraint. 3. Remove the safety belt anchor bolt.
- To install, tighten to 75 Nm (55 lb-ft).
4. Pull out at the bottom and remove the safety belt guide cover. 5. Release the backrest trim cover
J-clip.
6. Remove all the staples in the backrest support panel.
7. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
seat backrest foam pad.
Separate the hook-and-loop fasteners, invert the backrest trim cover and remove the hog rings.
8. NOTE:
- The inboard and outboard head restraint sleeves are not interchangeable.
- The head restraint sleeves incorporate an alignment tab that must face forward when installed.
Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube.
9. Separate the hook-and-loop fasteners. Remove the backrest trim cover.
- Feed the safety belt out through the backrest trim cover.
10. To install, reverse the removal procedure.
Seat Cushion Cover - Second Row, 40 Percent, Bench
SEAT CUSHION COVER - SECOND ROW, 40 PERCENT, BENCH
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9058
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9059
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9060
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9061
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9062
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9063
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9064
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9065
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9066
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9067
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9068
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9069
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9070
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9071
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Remove the second row, 40 percent of 60/40 bench seat.
2. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the cushion foam pad.
Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion
trim cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9072
3. To install, reverse the removal procedure.
Seat Cushion Cover - Second Row, 60 Percent, Bench
SEAT CUSHION COVER - SECOND ROW, 60 PERCENT, BENCH
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9073
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9074
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9075
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9076
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9077
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9078
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9079
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9080
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9081
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9082
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9083
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9084
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9085
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Remove the second row, 60 percent seat.
2. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the cushion foam pad.
Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion
trim cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9086
3. To install, reverse the removal procedure.
Seat Backrest Cover - Second Row, Bucket
SEAT BACKREST COVER - SECOND ROW, BUCKET
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9087
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9088
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9089
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9090
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9091
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9092
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9093
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9094
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9095
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9096
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9097
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9098
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9099
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. Remove the head restraint.
2. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
seat backrest foam pad.
Release the backrest trim cover lower J-clip, separate the hook-and-loop fasteners, remove 2 rows
of hog rings and invert the backrest trim cover
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9100
as high as it will go.
3. NOTE:
- The inboard and outboard head restraint sleeves are not interchangeable.
- The head restraint sleeves incorporate an alignment tab that must face forward when installed.
Squeeze together the tip of the head restraint sleeve and pull the sleeve out of the frame tube.
4. Remove the seat backrest trim cover. 5. To install, reverse the removal procedure.
Seat Cushion Cover - Second Row, Bucket
SEAT CUSHION COVER - SECOND ROW, BUCKET
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9101
Second Row, 60 Percent E-Z Entry Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9102
Second Row, 60 Percent E-Z Entry Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9103
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Second Row, 60 Percent E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9104
Second Row, 40 Percent E-Z Entry Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9105
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9106
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9107
Second Row, Bucket, Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9108
Second Row, Bucket, Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9109
Second Row, Bucket, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9110
Second Row, 60 Percent Bench, Backrest (Part 1)
Second Row, 60 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9111
Second Row, 60 Percent Bench, Cushion (Part 1)
Second Row, 60 Percent Bench, Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9112
Second Row, 40 Percent Bench, Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9113
Second Row, 40 Percent Bench, Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9114
Second Row, 40 Percent Bench, Cushion
Exploded View
Removal and Installation
1. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
seat cushion foam pad.
Release the cushion trim cover J-clips, separate the hook-and-loop fasteners and remove one row
of hog rings.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9115
2. Release the cable from the seat riser and remove the cushion trim cover. 3. To install, reverse
the removal procedure.
Seat Backrest Cover - Third Row
SEAT BACKREST COVER - THIRD ROW
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9116
Third Row Seat Backrest
Third Row Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9117
Third Row Seat Cushion (Part 2)
Exploded View
Removal and Installation
1. Fold the backrest not being serviced down. 2. Release the backrest trim cover J-clip at the top of
the trim cover by the head restraint.
- Pull the head restraint release strap through the backrest trim cover.
3. Remove the 2 head restraint-to-backrest frame bolts and remove the head restraint.
- To install, tighten to 25 Nm (18 lb-ft).
4. Remove 2 bolts and the hinge cover. 5. Remove 2 bolts and the latch cover. 6. Release the
backrest trim cover lower J-clip.
7. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the backrest trim cover side J-clips, hook-and-loop strips, invert and remove the backrest
trim cover.
8. To install, reverse the removal procedure.
Seat Cushion Cover - Third Row
SEAT CUSHION COVER - THIRD ROW
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9118
Third Row Seat Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9119
Third Row Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat
Backrest Cover - Front > Page 9120
Third Row Seat Cushion (Part 2)
Exploded View
Removal and Installation
1. Remove the third row seat from the vehicle. 2. Release the cushion trim cover retainers attached
to the bottom of the cushion frame.
3. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Invert the cushion trim cover, release the hook-and-loop strips and separate the cushion trim cover
from the cushion foam pad.
4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > Customer Interest: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose
Seat Cushion: Customer Interest Interior - Outside Seat Cushion Shield is Loose
TSB 07-25-10
12/24/07
LOOSE OUTSIDE SEAT CUSHION SHIELD- VEHICLES BUILT BEFORE 7/1/2007
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built before
7/1/2007 may exhibit a loose outside seat cushion shield. A new bracket was developed to prevent
the outside cushion shield from losing retention to the seat base.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Inspect for a retention bracket. (Figure 1)
a. If retention bracket is present do not continue with this TSB.
b. If no retention bracket is present proceed to Step 2.
2. Position the driver and passenger seats rearward.
3. Install the new retention bracket over the seat base wire support. (Figure 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > Customer Interest: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose > Page 9129
4. Align the retention bracket over the cushion side shield spring clip mounting boss hole and
attach the cushion side shield. (Figure 2)
NOTE
DO NOT REPLACE THE OUTSIDE CUSHION SHIELD IF THE FRONT SPRING CLIP IS LOOSE,
AS THE NEW BRACKET AND SCREW WILL PROVIDE THE PROPER RETENTION.
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
072510A 2006-2008 Explorer, 0.2 Hr.
Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket One Seat
072510B 2006-2008 Explorer, 0.3 Hr.
Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket Both Seats
DEALER CODING
CONDITION
BASIC PART NO. CODE
7862900 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose
Seat Cushion: All Technical Service Bulletins Interior - Outside Seat Cushion Shield is Loose
TSB 07-25-10
12/24/07
LOOSE OUTSIDE SEAT CUSHION SHIELD- VEHICLES BUILT BEFORE 7/1/2007
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
ISSUE Some 2006-2008 Explorer, Mountaineer and 2007-2008 Sport Trac vehicles built before
7/1/2007 may exhibit a loose outside seat cushion shield. A new bracket was developed to prevent
the outside cushion shield from losing retention to the seat base.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Inspect for a retention bracket. (Figure 1)
a. If retention bracket is present do not continue with this TSB.
b. If no retention bracket is present proceed to Step 2.
2. Position the driver and passenger seats rearward.
3. Install the new retention bracket over the seat base wire support. (Figure 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 07-25-10 > Dec > 07 > Interior - Outside Seat Cushion Shield is Loose > Page
9135
4. Align the retention bracket over the cushion side shield spring clip mounting boss hole and
attach the cushion side shield. (Figure 2)
NOTE
DO NOT REPLACE THE OUTSIDE CUSHION SHIELD IF THE FRONT SPRING CLIP IS LOOSE,
AS THE NEW BRACKET AND SCREW WILL PROVIDE THE PROPER RETENTION.
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
072510A 2006-2008 Explorer, 0.2 Hr.
Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket One Seat
072510B 2006-2008 Explorer, 0.3 Hr.
Mountaineer, 2007-2008 Sport Track: Install Outside Seat Cushion Shield Bracket Both Seats
DEALER CODING
CONDITION
BASIC PART NO. CODE
7862900 07
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cushion: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel
Brake Pedal Assy: All Technical Service Bulletins Brakes - Poor Brake Pedal Feel
TSB 09-1-6
01/26/09
IMPROVED BRAKE PEDAL FEEL AND FIRMNESS - BUILT BEFORE 5/31/2008
FORD: 2006-2008 Explorer 2007-2008 Explorer Sport Trac
MERCURY: 2006-2008 Mountaineer
This article supersedes TSB 08-2-8 to update the part list and add a production fix date.
ISSUE Some 2006-2008 Explorer, Mountaineer, and 2007-2008
Sport Trac vehicles built before 5/31/2008 may experience customer concerns with brake pedal
feel or firmness.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Bleed the brake system using the anti-lock brake system (ABS) hydraulic control unit (HCU)
bleeding procedure found in Workshop Manual (WSM), Section 206-00.
a. If the brake bleeding procedure resolves the concern, do not continue with this TSB and return
the vehicle to the customer.
b. If the brake bleeding procedure does not resolve the customer concern, replace the brake pedal
assembly.
2. Remove brake pedal assembly, Refer to WSM Section 206-06.
3. Install updated brake pedal assembly.
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
090106A 2006-2008 0.7 Hr.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System (Do Not Use With
2000A)
090106B 2006-2008 1.8 Hrs.
Explorer/Mountaineer, 2007-2008 Explorer Sport Trac: Bleed The Brake System, Replace The
Brake Pedal Assembly (Do Not Use With 2000A,
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cushion: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 9141
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Seat Cushion: > 09-1-6 > Jan > 09 > Brakes - Poor Brake Pedal Feel > Page 9147
13480A, 9818A8)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2455 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement
Seat Cushion: Removal and Replacement
SEAT CUSHION - THIRD ROW
Third Row Seat Backrest
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9150
Third Row Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9151
Third Row Seat Cushion (Part 2)
Exploded View
Removal and Installation
1. Position the backrest to the upright position. 2. Remove the third row seat from the vehicle.
3. NOTE: The backrest must be up to access the bolts.
Remove the latch-to-cushion frame bolt and the hinge-to-cushion frame bolt. To install, tighten to 25 Nm (18 lb-ft).
4. From under the front of the cushion frame, release the cushion trim cover from the studs to
access the 2 cushion pivot link assembly-to-cushion
frame nuts.
5. Remove the 2 cushion pivot link assembly-to-cushion frame nuts. Remove the cushion
assembly.
- To install, tighten to 22 Nm (16 lb-ft).
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9152
Seat Cushion: Overhaul
Seat Cushion - Front
SEAT CUSHION - FRONT
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9153
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9154
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9155
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9156
Passenger Seat Cushion (Part 2)
Disassembly and Assembly
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.
- The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing
an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt
retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in
pretensioner or air bag deployment and could result in personal injury.
- Never probe the connector on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9157
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
seat track. 3. Remove the front seat backrest.
4. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the hook-and-loop strips, remove the hog rings and separate the cushion trim cover from
the cushion foam pad.
Seat with heat
5. If necessary, remove the cushion heated seat mat and route out the wire harness through the
cushion foam pad opening.
All seats
6. To assemble, reverse the disassembly procedure. 7. Install the front seat backrest. 8. Install the
seat track. 9. Install the front seat and repower the SRS. If a passenger seat has been serviced, do
not prove out the SRS at this time.
Passenger seat
10. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Seat Cushion - Second Row, 40 Percent E-Z Entry
SEAT CUSHION - SECOND ROW, 40 PERCENT E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9158
Second Row, 40 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9159
Second Row, 40 Percent, E-Z Entry Cushion (Part 2)
Disassembly
1. Remove the second row 40 percent E-Z entry seat from the vehicle. 2. Lower the backrest and
position the seat to the E-Z entry position.
- The latch feet should be released from the mounting plate and the cushion and backrest must be
pivoted up.
3. Using the kneeling mechanism release handle on the backrest, pull the handle and position the
kneeling mechanism down in the fold flat load floor
position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism
will be in the fold flat load floor position.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9160
4. NOTE: The shock should be fully extended when removing.
Remove the shock from the seat assembly. Pry the retaining clip out and separate the shock at the mounting plate and cushion frame.
5. Remove the second row 40 percent E-Z entry seat backrest. 6. Remove 3 screws, recliner
handle and outboard recliner outer cover. 7. Remove 2 screws and the inboard recliner outer
cover. 8. Remove the 2 screws and the latch feet release bar. 9. Release all the cushion trim cover
retainers and pin-type retainers.
10. Remove the cushion trim cover and cushion foam pad from the cushion frame.
11. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn from
the cushion foam pad.
Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad.
12. Remove 2 outboard recliner-to-cushion frame bolts and separate the outboard recliner. 13.
Remove the outboard recliner inner cover.
14. Remove the outboard recliner.
1. Rotate the cable casing out of the outboard recliner.
2. NOTE: The cable ends are color coded/keyed to the levers.
Rotate the cable ends out of the outboard recliner levers.
3. Remove the outboard recliner.
15. Remove the 2 screws, pull to separate and remove the kneeling mechanism inboard leg inner
and outer covers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9161
16. Separate the cable to the kneeling mechanism inboard leg.
1. Turn and separate the cable casing retainer at the inboard side of the kneeling mechanism
inboard leg. 2. Separate the cable from the kneeling mechanism inboard leg release lever.
- Remove any cable casing retainers.
17. Remove 2 bolts, the spacer and the latch feet retracting link. 18. Remove the 2 screws and the
2 latch foot covers. 19. Separate the cable and casing from the outboard latch foot. Remove the
cable assembly. 20. Remove the screw and separate the kneeling mechanism release cable pivot
at the inboard recliner. 21. Remove the 2 screws, pull to separate and remove the kneeling
mechanism outboard leg inner and outer covers.
22. Separate the cable to the kneeling mechanism outboard leg and cushion frame.
1. Turn and separate the cable casing retainer at the inboard side of the outboard kneeling
mechanism leg. 2. Separate the cable from the outboard kneeling mechanism leg release lever. 3.
Separate any cable casing retainers to the cushion frame and remove the cable.
23. Remove the 2 inboard recliner-to-cushion frame bolts, the safety belt buckle and separate the
inboard recliner with recliner release shaft.
- If necessary, separate the recliner release shaft from the inboard recliner.
24. Remove the inboard recliner inner cover. 25. Remove the cushion frame.
- Remove the 2 kneeling mechanism-to-cushion frame bolts.
- Remove the 2 latch feet assembly-to-cushion frame bolt.
- Remove the cushion frame.
26. Using the release lever, manually release the inboard and outboard latch feet and remove the
latch feet assembly. 27. Remove the 2 nuts and remove the kneeling mechanism.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9162
Assembly
1. Position the kneeling mechanism to the mounting plate and install the nuts.
- Tighten to 41 Nm (30 lb-ft).
2. NOTE: Latch feet will hang down lower than the mounting plate, potentially causing the latch feet
to partially latch. Make sure the latch feet are
completely latched.
Position the latching feet assembly to the mounting plate strikers and latch the feet in place.
3. Install the cushion frame.
- Position the cushion frame to the latch feet assembly and kneeling mechanism.
- Install the 2 latch feet assembly-to-cushion frame bolts. Tighten to 45 Nm (33 lb-ft).
- Install the 2 kneeling mechanism-to-cushion frame bolts. Tighten to 45 Nm (33 lb-ft).
4. Position the recliner release shaft onto the inboard recliner release pivot stub. 5. Position the
inboard recliner and recliner release shaft to the cushion frame.
- Position the inboard recliner to the cushion frame with the recliner release shaft through the
cushion frame opening.
- Position the safety belt buckle to the inboard recliner forward bolt hole and install the 2 inboard
recliner-to-cushion frame bolts.
- Tighten to 55 Nm (41 lb-ft).
6. NOTE: The cable ends are color coded/keyed to the levers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9163
Position each keyed cable end to the outboard recliner lever and rotate to the locked position. Install the cable casing to the outboard recliner.
7. Position the outboard recliner release pivot stub into the recliner shaft and install the outboard
recliner-to-cushion frame bolts.
- Tighten to 55 Nm (41 lb-ft).
8. Route the outboard recliner short cable, attach the cable to the latch feet assembly outboard foot
and attach the cable casing retainers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9164
9. Route the outboard recliner long cable, attach it to the kneeling mechanism inboard leg and
attach all cable casing retainers.
10. Route the kneeling mechanism release cable, position the cable pivot at the inboard recliner
and install the screw. 11. Install the cable to the kneeling mechanism outboard leg and cushion
frame.
- Attach the cable to the kneeling mechanism outboard leg release lever.
- Position, turn and install the cable casing retainer at the inboard side of the kneeling mechanism
outboard leg.
- Attach any cable casing retainers.
12. Position the 2 latch foot covers and install the 2 screws. 13. Position the inner and outer covers
around the kneeling mechanism outboard leg and install the 2 screws. 14. Position the inner and
outer covers around the kneeling mechanism inboard leg and install the 2 screws. 15. Install the
latch feet retracting link.
- Position the spacer between the latch feet retracting link and inboard latch foot.
- Install the bolt through the latch feet retracting link and spacer and into the inboard latch foot.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9165
- Install the latch feet retracting link bolt into the kneeling mechanism inboard leg. Tighten to 8 Nm (71 lb-in).
16. Position the inboard and outboard recliner inner covers. 17. Align the cushion trim cover to the
cushion foam pad and attach the hook-and-loop strips. 18. Position the cushion foam pad and trim
cover to the cushion frame and attach the cushion trim cover retainers and pin-type retainers.
- Make sure the LATCH is accessible to the occupant.
19. Position the latch feet release bar and install the 2 screws. 20. Install the second row, 40
percent E-Z entry seat backrest. 21. Lower the backrest and position the seat to the E-Z entry
position.
- The latch feet should be released from the mounting plate and the cushion and backrest must be
pivoted up.
22. Using the kneeling mechanism release handle on the backrest, pull the handle and position the
kneeling mechanism down in the fold flat load floor
position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism
will be in the fold flat load floor position.
23. NOTE: The shock should be fully extended when installed.
Position and install the shock onto the seat assembly.
24. Install the second row, 40 percent E-Z entry seat into the vehicle. 25. Cycle the backrest down
and then back to the upright position. Make sure the inboard and outboard recliners simultaneously
and securely lock in
the upright position.
Seat Cushion - Second Row, 60 Percent, E-Z Entry
SEAT CUSHION - SECOND ROW, 60 PERCENT, E-Z ENTRY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9166
Second Row, 60 Percent, E-Z Entry Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9167
Second Row, 60 Percent, E-Z Entry Cushion (Part 2)
Disassembly
1. Remove the second row, 60 percent E-Z entry seat from the vehicle. 2. Lower the backrest and
position the seat to the E-Z entry position.
- The latch feet should be released from the mounting plate and the cushion and backrest must be
pivoted up.
3. Using the kneeling mechanism release handle on the backrest, pull the handle and position the
kneeling mechanism down in the fold flat load floor
position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism
will be in the fold flat load floor position.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9168
4. NOTE: The shock should be fully extended when removing.
Remove the shock from the seat assembly. Pry the retaining clip out and separate the shock from the seat assembly at each end.
5. Remove the second row 60 percent E-Z entry seat backrest. 6. Remove 3 screws, recliner
handle and outboard recliner outer cover. 7. Remove the 2 screws and the latch feet release bar. 8.
Release all the cushion trim cover retainers and pin-type retainers. 9. Remove the cushion trim
cover and cushion foam pad from the cushion frame.
10. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn from
the cushion foam pad.
Release the hook-and-loop strips and separate the cushion trim cover from the cushion foam pad.
11. Remove 2 outboard recliner-to-cushion frame bolts, pull out and separate the outboard recliner.
12. Remove the outboard recliner inner cover.
13. Remove the outboard recliner.
1. Rotate the cable casing out of the outboard recliner.
2. NOTE: The cable ends are color coded/keyed to the levers.
Rotate the cable ends out of the outboard recliner levers.
3. Remove the outboard recliner.
14. Remove the 2 screws, pull to separate and remove the kneeling mechanism inboard leg inner
and outer covers. 15. Remove the 2 screws, pull to separate and remove the kneeling mechanism
outboard leg inner and outer covers. 16. Remove the bolt and spacer and separate the latch feet
retracting link from the latch feet assembly.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9169
17. Release the tab and slide the latch feet retracting link retainer back.
18. Release the tab and remove the latch feet retracting link from the kneeling mechanism.
19. NOTE: Note the routing of the cable for installation.
Separate the cable to the kneeling mechanism inboard leg and cushion frame. 1. Turn and
separate the cable casing retainer at the inboard side of the kneeling mechanism inboard leg. 2.
Separate the cable from the kneeling mechanism inboard leg release lever.
- Remove the cable casing retainers from the cushion frame.
20. Remove the 2 screws and the 2 latch foot covers. 21. Separate the cable and casing from the
outboard latch foot, cushion support springs and remove the cable assembly. 22. Through the
opening in the cushion frame, remove the recliner release shaft.
23. NOTE: Note the routing of the cable for installation.
Separate the kneeling mechanism cable pivot at the inboard recliner.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9170
24. NOTE: Note the routing of the cable for installation.
Remove the kneeling mechanism release handle with cable. 1. Turn and separate the cable casing
retainer at the inboard side of the outboard kneeling mechanism leg. 2. Separate the cable from the
outboard kneeling mechanism leg release lever. 3. Separate any cable casing retainers to the
cushion frame and remove the kneeling mechanism release handle with cable.
25. Remove the cushion frame.
- Remove the cushion frame-to-kneeling mechanism bolt.
- Remove the cushion frame-to-latch foot assembly bolt.
- Remove the 2 inboard recliner-to-cushion frame bolts.
- Remove the cushion frame.
26. Remove the 2 bolts and the safety belt buckles. 27. Remove the inboard recliner.
- Remove the inboard recliner-to-kneeling mechanism bolt.
- Remove the inboard recliner-to-latch feet assembly bolt.
- Remove the inboard recliner. Remove the inboard recliner inner cover.
28. Using the release levers, manually release the inboard and outboard latch feet and remove the
latch feet assembly from the mounting plate. 29. Remove the 2 kneeling mechanism-to-mounting
plate nuts and remove the kneeling mechanism.
Assembly
1. Position the kneeling mechanism to the mounting plate and install the 2 kneeling
mechanism-to-mounting plate nuts.
- Tighten to 41 Nm (30 lb-ft).
2. NOTE: Latch feet will hang down lower than the mounting plate, potentially causing the latch feet
to partially latch. Make sure the latch feet are
completely latched.
Position the latch feet assembly to the mounting plate strikers and latch the feet in place.
3. Install the inboard recliner inner cover. 4. Position the inboard recliner.
- Position the inboard recliner to the kneeling mechanism and latch feet assembly.
- Hand start the latch feet assembly-to-inboard recliner bolt.
- Hand start the kneeling mechanism-to-inboard recliner bolt.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9171
5. Position the recliner release shaft onto the inboard recliner release pivot stub.
6. Position the cushion frame to the inboard recliner with the recliner release shaft through the
cushion frame opening. 7. Hand start the 2 inboard recliner-to-cushion frame bolts. 8. Hand start
the cushion frame-to-latch foot assembly bolt and the cushion frame-to-kneeling mechanism bolt.
9. Install the bolts.
- Install the inboard recliner-to-latch feet assembly bolt. Tighten to 55 Nm (41 lb-ft).
- Install the inboard recliner-to-kneeling mechanism bolt. Tighten to 55 Nm (41 lb-ft).
- Install the cushion frame-to-latch foot assembly bolt. Tighten to 55 Nm (41 lb-ft).
- Install the cushion frame-to-kneeling mechanism bolt. Tighten to 55 Nm (41 lb-ft).
- Install the inboard recliner-to-cushion frame rear bolt. Tighten to 40 Nm (30 lb-ft).
- Install the inboard recliner-to-cushion frame front bolt. Tighten to 40 Nm (30 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9172
10. NOTE: The cable ends are color coded/keyed to the levers.
Position each keyed cable end to the outboard recliner lever and rotate to the locked position. Install the cable casing to the outboard recliner.
11. Install the outboard recliner inner cover.
12. NOTE: The outboard recliner inner cover has been removed for clarity.
Position the outboard recliner release pivot stub into the recliner shaft and install the 2 outboard
recliner-to-cushion frame bolts. Tighten to 55 Nm (41 lb-ft).
13. Install the outboard recliner short cable to the latch feet assembly outboard foot and attach all
cable casing retainers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9173
14. Install the outboard recliner long cable to the kneeling mechanism inboard leg and attach all
cable casing retainers.
15. Route the kneeling mechanism release cable, position the kneeling mechanism release cable
pivot at the inboard recliner and attach all cable casing
retainers.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9174
16. Make sure the inboard recliner pin is through the cable pivot. 17. Install the kneeling
mechanism release cable to the kneeling mechanism outboard leg.
- Attach the cable to the kneeling mechanism outboard leg release lever.
- Position, turn and install the cable casing retainer at the inboard side of the kneeling mechanism
outboard leg.
- Attach any cable casing retainers.
18. Position the inner and outer covers around the kneeling mechanism outboard leg and install the
2 screws. 19. Position the inner and outer covers around the kneeling mechanism inboard leg and
install the 2 screws. 20. Position the 2 latch foot covers and install the 2 screws. 21. Position the
latch feet retracting link retainer onto the latch feet retracting link shaft. 22. Position the latch feet
retracting link into the kneeling mechanism coupler engaging the retainer.
- The kneeling mechanism coupler is part of the kneeling mechanism.
23. Slide the latch feet retracting link retainer back to the kneeling mechanism coupler, engaging
the retainer. 24. Position the spacer between the latch feet retracting link and outboard latch foot
and install the bolt.
25. Align the safety belt buckle anti-rotation tabs to the cushion frame openings and install the 2
bolts.
- Tighten to 40 Nm (30 lb-ft).
26. Align the cushion trim cover to the cushion foam pad and attach the hook-and-loop strips. 27.
Position the cushion foam pad and trim cover to the cushion frame and attach the cushion trim
cover retainers and pin-type retainers.
- Pull the 2 safety belt buckles through the cushion trim cover and foam pad.
- Make sure the LATCH is accessible to the occupant.
28. Position the latch feet release bar and install the 2 screws. 29. Install the second row, 60
percent E-Z entry seat backrest. 30. Lower the backrest and position the seat to the E-Z entry
position.
- The latch feet should be released from the mounting plate and the cushion and backrest must be
pivoted up.
31. Using the kneeling mechanism release handle on the backrest, pull the handle and position the
kneeling mechanism down in the fold flat load floor
position. The cushion and backrest of the seat will be in the E-Z entry position and the kneeling mechanism
will be in the fold flat load floor position.
32. NOTE: The shock should be fully extended when installed.
Position and install the shock onto the seat assembly.
33. Install the second row, 60 percent E-Z entry seat into the vehicle. 34. Cycle the backrest down
and then back to the upright position. Make sure the inboard and outboard recliners simultaneously
and securely lock in
the upright position.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9175
Seat Cushion - Second Row, 40 Percent, Bench
SEAT CUSHION - SECOND ROW, 40 PERCENT, BENCH
Disassembly and Assembly
1. Remove the second row, 40 percent of 60/40 bench seat. 2. Remove the second row, 40
percent of 60/40 bench seat backrest.
3. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
seat cushion foam pad.
Release the J-clips, separate the hook-and-loop fasteners and remove the seat cushion trim cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9176
4. Remove the cushion foam pad. 5. Remove the cushion pad supports. 6. To assemble, reverse
the disassembly procedure.
Seat Cushion - Second Row, 60 Percent, Bench
SEAT CUSHION - SECOND ROW, 60 PERCENT, BENCH
Part 1
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Removal and Replacement > Page 9177
Part 2
Disassembly and Assembly
1. Remove the second row, 60 percent bench seat. 2. Remove the second row, 60 percent bench
seat backrest.
3. CAUTION: Use care when separating the cushion trim cover from the hook-and-loop strip, or the
hook-and-loop strip can be torn from
the cushion foam pad.
Release the J-clips, separate the hook-and-loop fasteners, remove the hog rings and the cushion
trim cover.
4. Remove the cushion foam pad. 5. Remove 2 cushion pad supports. 6. Remove the screw and
the release handle. 7. Remove the 3 screws and the latch cover. 8. Remove the 2 lower outboard
latch bolts.
- To install, tighten to 40 Nm (30 lb-ft).
9. Remove the remaining lower inboard latch bolt.
- To install, tighten to 75 Nm (55 lb-ft).
10. CAUTION: Do not detach the latch cable from the seat latches. The latch assembly is
synchronized; if disassembled, the latch assembly
may not operate correctly.
Remove the latch assembly. Do not separate or disassemble the latch assembly components.
11. To assemble, reverse the disassembly procedure.
Seat Cushion - Second Row, Bucket
SEAT CUSHION - SECOND ROW, BUCKET
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Removal and Replacement > Page 9178
Part 1
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Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9179
Part 2
Disassembly and Assembly
NOTE: LH seat shown, RH similar.
1. Remove the second row bucket seat. 2. Remove the second row bucket seat backrest. 3.
Remove the screw and the release handle. 4. Remove the 2 screws and the 2 LH latch covers. 5.
Remove the 2 screws and the 2 RH latch covers.
6. CAUTION: Use care when separating the seat upholstery from the hook-and-loop strip, or the
hook-and-loop strip can be torn from the
seat cushion foam pad.
Release the cushion trim cover J-clips, separate the hook-and-loop fasteners and remove one row
of hog rings.
7. Release the cable from the seat riser and remove the cushion trim cover. 8. Remove the seat
cushion foam pad. 9. Remove the 2 lower latch cover screws and the 2 LH lower latch covers.
10. NOTE: The left and right latches with cables are one assembly and should not be separated.
Remove the 4 latch bolts and the latch pivot. To install, tighten to 40 Nm (30 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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11. Remove the 2 latch nuts and separate the latch assembly.
- To install, tighten to 40 Nm (30 lb-ft).
12. NOTE: On assembly, route the cable as shown.
Remove the riser attachment cable and the latch assembly.
13. Remove the torsion rod and the cushion pad support. 14. Remove the front spring hinge bolts,
springs and seat cushion frame assembly.
- To install, tighten to 23 Nm (17 lb-ft).
15. To assemble, reverse the disassembly procedure.
Seat Cushion - Third Row Third Row Seat Cushion
SEAT CUSHION - THIRD ROW
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9181
Third Row Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair >
Removal and Replacement > Page 9182
Third Row Seat Cushion (Part 2)
Disassembly and Assembly
1. Remove the third row seat from the vehicle. 2. Remove the third row cushion. 3. Release the
cushion trim cover J-clips attached to the bottom of the cushion frame. 4. Remove the cushion
foam pad and trim cover from the cushion frame.
5. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Invert the cushion trim cover, release the hook-and-loop strips and separate the cushion trim cover
from the cushion foam pad.
6. To assemble, reverse the disassembly procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions
Seat Heater: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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Information and Instructions > Page 9188
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Information and Instructions > Page 9189
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Information and Instructions > Page 9190
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Symbols Part 2
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Information and Instructions > Page 9192
Symbols Part 3
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Information and Instructions > Page 9193
Symbols Part 4
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Information and Instructions > Page 9194
Symbols Part 5
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Information and Instructions > Page 9195
Seat Heater: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9196
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9197
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9198
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9199
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9200
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9201
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9203
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9204
Seat Heater: Connector Views
C335
C365
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9205
C334
C364
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram
Information and Instructions > Page 9206
Seat Heater: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
119-1
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page
9210
C2347
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch
Seat Heater Switch: Service and Repair Heated Seat Switch
HEATED SEAT SWITCH
Removal and Installation
1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center
console door, remove the 2 screws and pull up on the console finish panel to release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out
to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6.
Pull out to release the retainers and separate the instrument panel center finish panel. 7.
Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated
windshield switch pack. 8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9213
Seat Heater Switch: Service and Repair Seat Control Switch
SEAT CONTROL SWITCH
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9214
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9215
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9216
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9217
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9218
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9219
Passenger Seat Cushion (Part 2)
Exploded View
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
cushion side shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9220
1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the
manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5.
From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side
shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap
from the cushion side shield. 8. Remove the seat control switch knob and separate the seat control
switch from the cushion side shield.
- Remove the cushion side shield.
3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5.
Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out
the SRS at this time.
Passenger seat
6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Heated Seat Switch > Page 9221
Seat Heater Switch: Service and Repair Seat Control Switch - Third Row
SEAT CONTROL SWITCH - THIRD ROW
Removal and Installation
1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel. 2.
Disconnect the third row seat control switch(es), release the retainers and remove the third row
seat control switch(es). 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair
Seat Latch: Service and Repair
SEAT LATCH - THIRD ROW, MANUAL
Removal and Installation
LH or RH latch
1. Position both of the third row seat backrests up. 2. Remove the RH latch-to-cushion frame bolt.
- To install, tighten to 25 Nm (18 lb-ft).
LH latch
3. Remove the LH latch-to-cushion frame bolt.
- To install, tighten to 25 Nm (18 lb-ft).
LH or RH latch
4. Position the third row seat LH backrest down. 5. Remove the vehicle jack.
6. Remove the 2 bolts and the vehicle jack mounting bracket. 7. Remove the 2 screws and the RH
latch cover. 8. Separate the cable and casing from the RH latch.
9. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the RH seat backrest trim cover lower and inboard J-clips and roll the backrest trim cover
up to access the 2 RH latch-to-backrest frame bolts.
10. Remove the 2 RH latch-to-backrest frame bolts.
- To install, tighten to 25 Nm (18 lb-ft).
11. Remove the floor mounting bracket center front and rear nuts.
- To install, tighten to 40 Nm (30 lb-ft).
12. Remove the 2 latch-to-floor mounting bracket nuts.
- To install, tighten to 22 Nm (16 lb-ft).
13. Remove the RH latch.
LH latch
14. Position the third row seat LH backrest up and the RH backrest down. 15. Remove the 2
screws and the LH latch cover. 16. Separate the cable and casing from the LH latch.
17. CAUTION: Use care when separating the seat back trim cover from the hook-and-loop strip, or
the hook-and-loop strip can be torn
from the backrest foam pad.
Release the LH seat backrest trim cover lower and inboard J-clips and roll the backrest trim cover
up to access the 2 LH latch-to-backrest frame bolts.
18. Remove the 2 LH latch-to-backrest frame bolts.
- To install, tighten to 25 Nm (18 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Page
9225
19. Remove the LH latch. 20. Remove the safety belt buckle assembly-to-latch nut and remove the
safety belt buckle assembly.
- To install, tighten to 75 Nm (55 lb-ft).
Both latches
21. To install, reverse the removal procedure.
- The latch(es) must be in the backrest fold down position to install.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair
Seat Track: Service and Repair
SEAT TRACK
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9229
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9230
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9231
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9232
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9233
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9234
Passenger Seat Cushion (Part 2)
Exploded View
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9235
Passenger seat with failed horizontal motor
2. To remove the occupant classification sensor (OCS) rails, remove the 2 horizontal screw block
bolts. This will allow the power seat tracks to move
independently of each other for access to the 8 OCS rail bolts.
Passenger seat receiving a new seat track
3. Remove the inboard and outboard OCS rails.
Passenger seat not receiving a new seat track
4. NOTE: Note the position and the routing of the OCS sensor wiring, connector and wiring
retainers for installation.
Detach the 2 OCS wiring retainers at each OCS rail. Then using a suitable tool, release the tab and
disconnect the RH and LH OCS rail electrical connectors.
All seats
5. Remove the cushion side shield.
1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the
manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5.
From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side
shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap
from the cushion side shield.
- If equipped with a manual seat track, remove the cushion side shield.
8 If equipped with power seats, remove the seat control switch knob and separate the seat control
switch from the cushion side shield. Remove the cushion side shield.
Power seat
6. Separate the seat control switch wire harness pin-type retainer from the cushion frame.
Driver seat
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9236
7. Disconnect the SRS seat position sensor.
8. Driver seat with 10-way power, disconnect the backrest power feed electrical connector and
route out the wire harness.
- Release any wire harness retainers.
Heated seat
9. NOTE: Passenger seat shown, driver seat similar.
Disconnect the cushion and backrest heated seat mat electrical connectors.
All seats
10. Release the pin-type retainers, disconnect and route out the side air bag module electrical
connector and wire harness. 11. Remove the safety belt buckle and pretensioner electrical
connector cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Page
9237
12. Disconnect the safety belt buckle and pretensioner electrical connector and safety belt buckle
switch electrical connector. 13. Release all the cushion trim cover retainers. 14. Remove the seat
cushion foam pad and cushion trim cover. 15. Remove the 4 cushion frame-to-seat track nuts and
the seat track.
- To install, tighten to 36 Nm (27 lb-ft).
Driver seat with failed horizontal motor
16. If necessary, remove the inboard horizontal screw block bolt. This will allow the inboard power
seat track to move independently so the safety belt
buckle and pretensioner can be removed.
All seats
17. To install, reverse the removal procedure. 18. Install the front seat and repower the SRS. If a
passenger seat has been serviced, do not prove out the SRS at this time.
Passenger seat
19. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information >
Locations
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information >
Locations > Page 9241
C366
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door
Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Removal and Installation
1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3.
Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9247
Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Removal and Installation
1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch
counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9248
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Removal and Installation
1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch
counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9249
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Removal and Installation
1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and
remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch >
Component Information > Locations > Page 9253
C2089
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Lock Switch, Passenger Side
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Locations > Door Lock Switch, Passenger Side > Page 9258
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Door Lock Switch, Driver Side
C505
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Door Lock Switch, Driver Side > Page 9261
C605
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9262
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9263
Power Door Lock Switch: Service and Repair
DOOR LOCK CONTROL SWITCH
Removal and Installation
NOTE: The LH side is shown, the RH side is similar.
1. Remove the interior door handle cover. 2. Remove the front door switch bezel.
- Release the 4 retaining tabs.
3. Disconnect the door lock control switch and window control switch electrical connectors. 4.
Remove the door lock control switch.
- Release the 4 retaining tabs.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Page 9264
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9268
C527
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9269
Power Mirror Switch: Testing and Inspection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9270
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 9271
Power Mirror Switch: Service and Repair
EXTERIOR MIRROR CONTROL SWITCH
Removal and Installation
1. Remove the front door trim panel. 2. Remove the exterior mirror control switch from the front
door trim panel. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations
View 151-20 (Driver Seat)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Locations > Page 9275
Power Seat Switch: Diagrams
C352
C3016
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 9278
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Page 9279
Power Seat Switch: Service and Repair
MEMORY SET SWITCH
Removal and Installation
1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center
console door, remove the 2 screws and pull up on the console finish panel to release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out
to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6.
Pull out to release the retainers and separate the instrument panel center finish panel. 7.
Disconnect the electrical connector, release the 4 tabs and remove the memory SET switch. 8. To
install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Belt Tower Position Sensor
> Component Information > Description and Operation
Seat Belt Tower Position Sensor: Description and Operation
SEAT TRACK POSITION SENSOR
The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat
track position sensor informs the RCM of the driver seat position. Based on programmed limits, the
seat track position sensor will inform the RCM of the driver seat position. The RCM uses this
information in determining the deployment rate of the dual-stage driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Locations > Page 9286
C2347
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch
Seat Heater Switch: Service and Repair Heated Seat Switch
HEATED SEAT SWITCH
Removal and Installation
1. Position the gear selector to NEUTRAL. 2. Remove the console trim ring. 3. Open the center
console door, remove the 2 screws and pull up on the console finish panel to release the retainers.
4. Disconnect the power point electrical connector and remove the console finish panel. 5. Pull out
to release the retainers and separate the instrument panel center lower RH and LH finish panels. 6.
Pull out to release the retainers and separate the instrument panel center finish panel. 7.
Disconnect the electrical connector, release the 4 tabs and remove the heated seat/heated
windshield switch pack. 8. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9289
Seat Heater Switch: Service and Repair Seat Control Switch
SEAT CONTROL SWITCH
Special Tool(s)
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9290
Front Seat Backrest (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9291
Front Seat Backrest (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9292
Driver Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9293
Driver Seat Cushion (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9294
Passenger Seat Cushion (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9295
Passenger Seat Cushion (Part 2)
Exploded View
Removal and Installation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an airbag module. This will reduce the risk of injury in the event of an
accidental deployment.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the
SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All seats
1. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the
cushion side shield.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9296
1. If equipped, remove the clip and manual recline handle. 2. If equipped, pull and remove the
manual lumbar control knob. 3. Remove the scrivet. 4. Release the cushion side shield front clip. 5.
From under the cushion side shield, release the 3 hook retainers. 6. Pull out on the cushion side
shield at the back and release the pin-type retainer. 7. Separate the cushion trim cover elastic strap
from the cushion side shield. 8. Remove the seat control switch knob and separate the seat control
switch from the cushion side shield.
- Remove the cushion side shield.
3. Disconnect and remove the seat control switch. 4. To install, reverse the removal procedure. 5.
Install the front seat and repower the SRS. If a passenger seat has been serviced, do not prove out
the SRS at this time.
Passenger seat
6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove
out the SRS.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Heated Seat Switch > Page 9297
Seat Heater Switch: Service and Repair Seat Control Switch - Third Row
SEAT CONTROL SWITCH - THIRD ROW
Removal and Installation
1. Pull out on the third row seat control switch bezel and separate from the LH quarter trim panel. 2.
Disconnect the third row seat control switch(es), release the retainers and remove the third row
seat control switch(es). 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch
> Component Information > Service and Repair
Sunroof / Moonroof Limit Switch: Service and Repair
ROOF OPENING PANEL CONTROL SWITCH
Removal and Installation
1. Remove the overhead console. 2. Disconnect the overhead console electrical connectors.
3. Disengage the clips and remove the switch from the overhead console. 4. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Locations > Page 9304
Sunroof / Moonroof Switch: Diagrams
C912
C9001
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Explorer / Mountaineer
Sound Proofing / Insulation: Description and Operation Explorer / Mountaineer
INSULATION
Insulation is installed:
- under the hood.
- above and below the instrument panel.
- at the cowl side panels.
- over the front and rear tunnel.
- over the front and rear floor pans.
- inside the B-, C- and D-pillars.
It has heat-bondable mastic deadeners for improved NVH characteristics.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Explorer / Mountaineer > Page 9309
Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators
Sound Deadeners and Insulators
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear
protective equipment as directed. Examples may include but are not limited to respirators and
chemically resistant gloves. Failure to follow these instructions may result in serious personal
injury.
NOTICE:
- Mastic is made of a combustible material and should be removed prior to carrying out welding
procedures to the area. Heat zones from welding near the mastic may cause the mastic material to
burn.
- Corrosion protection must be restored to the area AFTER the mastic material is applied.
Corrosion protection products may be wax based and loss of adhesion may occur.
NOTE:
- The following illustrations serve as a reference to indicate mastic patch (butyl pad) locations.
Additional insulators and sound deadeners are used beyond those indicated in the illustration.
- To restore the vehicle to design intent, missing or damaged sound deadeners and insulators
should be installed new with the correct service replacement component.
Sound Deadeners and Insulators - Explorer Sport Trac
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Explorer / Mountaineer > Page 9310
Sound Deadeners and Insulators - Explorer/Mountaineer
1. NOTE: In applications where mastic material is applied as a pumpable material at the factory,
replacement of missing or damaged mastic is
acceptable in the form of cut-to-fit butyl pad(s) or pumpable mastic material(s) when carrying out
repairs.
Whenever replacement of an existing mastic insulator is carried out, the surface must be
thoroughly cleaned to make sure correct adhesion will occur. The surface should be 10°C (50°F) or
greater before applying the mastic. The use of a heat gun to warm the metal surface will aid in
adhesion.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair
Tailgate Latch: Service and Repair
TAILGATE LATCH
Removal and Installation
1. Open and support the tailgate. 2. Remove the 7 bolts, the 4 pin-type retainers and the tailgate
access panel.
- To install, tighten to 5 Nm (44 lb-in).
3. Open the clip and release the tailgate latch actuating rod from the tailgate remote control. 4.
Release the tailgate latch actuating rod locator from the tailgate. 5. Remove the 2 bolts and the
tailgate latch.
- To install, tighten to 25 Nm (18 lb-ft).
6. Remove the tailgate latch actuating rod. 7. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and
Repair
Tailgate Release Handle: Service and Repair
TAILGATE RELEASE HANDLE
Removal and Installation
1. Remove the tailgate latch remote control. 2. Remove the tailgate release handle. 3. To install,
reverse the removal procedure.
- Lubricate the tailgate release handle after installation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service
Bulletins > Customer Interest for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate
Tailgate Striker: Customer Interest Body - Rattle Noise From Tailgate
TSB 07-25-2
12/24/07
TAILGATE STRIKER - NOISE/RATTLE
FORD: 2004-2005 Explorer Sport Trac 2004-2008 F-150, F-Super Duty 2007-2008 Explorer Sport
Trac
LINCOLN: 2006-2008 Mark LT
ISSUE Some 2004-2008 F-Super Duty and F-150, 2006-2008 Mark LT, and 2004-2005 and
2007-2008 Explorer Sport Trac vehicles with a customer complaint of a noise or rattle in the
tailgate may have worn tailgate striker sleeves. This condition may be found on vehicles used in
severe conditions such as fleet applications or repetitive rough road/off-road applications.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Remove the tailgate striker bolt using a T50 Torx bit.
2. Replace the tailgate striker with a new striker.
3. Align the tailgate striker up/down to the tailgate latch and adjust in/out for margin flushness.
4. Torque the new tailgate striker to 30 lb-ft +/- 4 lb-ft (40 N.m +/- 6 N.m).
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
072502A 2004-2008 F-150, F-Super 0.2 Hr.
Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace One
Tailgate Striker, Includes Time To Align Tailgate (Do Not Use With 40442A)
072502B 2004-2008 F-150, F-Super 0.3 Hr.
Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace Both
Tailgate Strikers, Includes Time To Align Tailgate (Do Not Use With 40442A)
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service
Bulletins > Customer Interest for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate > Page 9326
CONDITION
BASIC PART NO. CODE
99404A42 30
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate
Tailgate Striker: All Technical Service Bulletins Body - Rattle Noise From Tailgate
TSB 07-25-2
12/24/07
TAILGATE STRIKER - NOISE/RATTLE
FORD: 2004-2005 Explorer Sport Trac 2004-2008 F-150, F-Super Duty 2007-2008 Explorer Sport
Trac
LINCOLN: 2006-2008 Mark LT
ISSUE Some 2004-2008 F-Super Duty and F-150, 2006-2008 Mark LT, and 2004-2005 and
2007-2008 Explorer Sport Trac vehicles with a customer complaint of a noise or rattle in the
tailgate may have worn tailgate striker sleeves. This condition may be found on vehicles used in
severe conditions such as fleet applications or repetitive rough road/off-road applications.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Remove the tailgate striker bolt using a T50 Torx bit.
2. Replace the tailgate striker with a new striker.
3. Align the tailgate striker up/down to the tailgate latch and adjust in/out for margin flushness.
4. Torque the new tailgate striker to 30 lb-ft +/- 4 lb-ft (40 N.m +/- 6 N.m).
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
072502A 2004-2008 F-150, F-Super 0.2 Hr.
Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace One
Tailgate Striker, Includes Time To Align Tailgate (Do Not Use With 40442A)
072502B 2004-2008 F-150, F-Super 0.3 Hr.
Duty, 2006-2008 Mark LT and 2004-2005 and 2007-2008 Explorer Sport Trac: Replace Both
Tailgate Strikers, Includes Time To Align Tailgate (Do Not Use With 40442A)
DEALER CODING
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Striker > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Tailgate Striker: > 07-25-2 > Dec > 07 > Body - Rattle Noise From Tailgate >
Page 9332
CONDITION
BASIC PART NO. CODE
99404A42 30
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component
Information > Service and Repair > Tonneau Cover Latch
Truck Bed Cover Latch: Service and Repair Tonneau Cover Latch
TONNEAU COVER LATCH
Removal and Installation
NOTE: Rear tonneau cover latch shown, front tonneau cover latch similar.
1. Remove the tonneau cover latch bolts.
2. Disconnect the tonneau cover cable.
1 Disconnect the tonneau cover cable conduit.
2 Disconnect the tonneau cover cable end.
3. Remove the tonneau cover latch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component
Information > Service and Repair > Tonneau Cover Latch > Page 9339
Truck Bed Cover Latch: Service and Repair Tonneau Cover Latch Release Cable
TONNEAU COVER LATCH RELEASE CABLE
Removal and Installation
NOTE: Rear tonneau cover latch release cable shown, front tonneau cover latch release cable
similar.
1. Remove the tonneau cover latches.
2. Disconnect the tonneau cover latch release cable.
1 Remove the tonneau cover latch release cable bolts.
2 Disconnect the tonneau cover latch release cable locking clip.
3. Remove the tonneau cover latch release cable. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Handle > Component Information > Service and Repair
Truck Bed Storage Compartment Handle: Service and Repair
PICKUP BED STORAGE COMPARTMENT RELEASE HANDLE
Removal and Installation
1. Remove the 2 pickup bed storage compartment release handle bolts.
- To install, tighten to 12 Nm (9 lb-ft).
2. CAUTION: Do not allow the pickup bed storage compartment lid to close until the latch has been
connected to the cable. If the lid is
closed prior to attaching the cable to the latch, releasing the latch is extremely difficult.
Remove the pickup bed storage compartment latch.
3. NOTE: Note the routing of the pickup bed storage compartment release cable.
Release the routing clips and remove the pickup bed storage compartment release handle and
cable as an assembly.
4. To install, reverse the removal procedures.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side
Compartment
Truck Bed Storage Compartment Hinge: Service and Repair Pickup Bed Storage Compartment
Hinge - Side Compartment
PICKUP BED STORAGE COMPARTMENT HINGE - SIDE COMPARTMENT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side
Compartment > Page 9348
Part 2
Exploded View
Removal and Installation
1. Remove the side compartment lid.
2. NOTE:
- The side compartment hinge is installed prior to the storage compartment seal.
- The surface of the compartment lid must be thoroughly cleaned before installing the new hinge.
Remove the storage compartment hinge. Remove the storage compartment seal.
- Remove the storage compartment hinge.
- Clean the lid surface of any residual seal material.
- Scuff the seal surface area.
- Apply adhesive promoter.
- Apply pressure to the hinge surface with a roller and allow seal to cure before installation for one
hour.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side
Compartment > Page 9349
Truck Bed Storage Compartment Hinge: Service and Repair Pickup Bed Storage Compartment
Hinge - Front Compartment
PICKUP BED STORAGE COMPARTMENT HINGE - FRONT COMPARTMENT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Hinge > Component Information > Service and Repair > Pickup Bed Storage Compartment Hinge - Side
Compartment > Page 9350
Part 2
Exploded View
Removal and Installation
1. Remove the front compartment lid. 2. Remove the pickup bed. 3. Remove the front compartment
lid hinge nuts from the front of the pickup bed.
- To install, tighten to 12 Nm (9 lb-ft).
4. Remove the front compartment lid hinge from the pickup box. 5. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Latch > Component Information > Service and Repair
Truck Bed Storage Compartment Latch: Service and Repair
PICKUP BED STORAGE COMPARTMENT LATCH
Removal and Installation
1. Remove the 3 pickup bed storage compartment latch bolts.
- To install, tighten to 12 Nm (9 lb-ft).
2. CAUTION: Do not allow the pickup bed storage compartment lid to close until the latch has been
connected to the cable. If the lid is
closed prior to attaching the cable to the latch, releasing the latch is extremely difficult.
Disconnect the pickup bed storage compartment release cable from the pickup bed storage
compartment latch.
3. Remove the pickup bed storage compartment latch. 4. To install, reverse the removal
procedures.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side
Compartment
Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage
Compartment Seal - Side Compartment
PICKUP BED STORAGE COMPARTMENT SEAL - SIDE COMPARTMENT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side
Compartment > Page 9358
Part 2
Exploded View
Removal and Installation
1. Remove the side compartment lid.
2. NOTE: The storage compartment seal is installed over the hinge assembly.
Remove the storage compartment seal from the storage compartment. Remove any adhesive or residual seal material.
- Clean the lid surface with a 50/50 solution of alcohol and water.
- Apply adhesive promotor.
- Apply seal.
- Apply pressure to the seal with a roller and allow seal to cure before installation for one hour.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side
Compartment > Page 9359
Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage
Compartment Seal - Front Compartment
PICKUP BED STORAGE COMPARTMENT SEAL - FRONT COMPARTMENT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage
Compartment Weatherstrip > Component Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side
Compartment > Page 9360
Part 2
Exploded View
Removal and Installation
1. Remove the front compartment lid. 2. Remove the storage compartment seal from the storage
compartment.
- Remove any adhesive or residual seal material.
- Clean the lid surface with a 50/50 solution of alcohol and water.
- Apply adhesive promotor.
- Apply seal.
- Apply pressure to the seal with a roller and allow seal to cure before installation for one hour.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
1. Remove the wiper pivot arms.
CAUTION: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the
cowl panel.
2. Pry up on the front of the cowl panel to release it from the retaining clips. 3. Remove the cowl
panel grille. 4. Separate the left cowl panel from the right cowl panel by releasing the retaining
clips. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component
Information > Service and Repair
Front Door Window Glass Weatherstrip: Service and Repair
DOOR GLASS TOP RUN - FRONT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component
Information > Service and Repair > Page 9370
Part 2
Exploded Views
Removal and Installation
1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door
glass top run channel assembly bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Remove the front door glass top run channel assembly through the top opening of the front door.
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component
Information > Service and Repair
Rear Door Window Glass Weatherstrip: Service and Repair
DOOR GLASS TOP RUN - REAR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component
Information > Service and Repair > Page 9374
Part 2
Exploded View
Removal and Installation
1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door
glass top run assembly bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Remove the rear door glass top run channel assembly.
- Remove the rear door glass top run channel assembly through the top opening of the rear door.
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component
Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment
Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage
Compartment Seal - Side Compartment
PICKUP BED STORAGE COMPARTMENT SEAL - SIDE COMPARTMENT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component
Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9379
Part 2
Exploded View
Removal and Installation
1. Remove the side compartment lid.
2. NOTE: The storage compartment seal is installed over the hinge assembly.
Remove the storage compartment seal from the storage compartment. Remove any adhesive or residual seal material.
- Clean the lid surface with a 50/50 solution of alcohol and water.
- Apply adhesive promotor.
- Apply seal.
- Apply pressure to the seal with a roller and allow seal to cure before installation for one hour.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component
Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9380
Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage
Compartment Seal - Front Compartment
PICKUP BED STORAGE COMPARTMENT SEAL - FRONT COMPARTMENT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Body and Frame > Weatherstrip > Truck Bed Storage Compartment Weatherstrip > Component
Information > Service and Repair > Pickup Bed Storage Compartment Seal - Side Compartment > Page 9381
Part 2
Exploded View
Removal and Installation
1. Remove the front compartment lid. 2. Remove the storage compartment seal from the storage
compartment.
- Remove any adhesive or residual seal material.
- Clean the lid surface with a 50/50 solution of alcohol and water.
- Apply adhesive promotor.
- Apply seal.
- Apply pressure to the seal with a roller and allow seal to cure before installation for one hour.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations >
Deactivator Switch > Page 9387
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams >
Deactivator Switch
C277
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams >
Deactivator Switch > Page 9390
C278
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Brake Pedal Position (BPP) Switch > Page 9393
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS) Brake
Deactivator Switch
BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Page 9394
Brake Switch (Cruise Control): Service and Repair
SPEED CONTROL DEACTIVATOR SWITCH
Removal
CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the speed control deactivator switch. Do not install the speed control deactivator switch
without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the
brake pedal when removing or installing the speed control deactivator switch, as misadjustment or
damage to the switch may occur.
1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise
45 degrees and remove the speed control deactivator switch.
Installation
NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the
proper position. Do not pull up or push down on the pedal during installation. Initial installation of
the speed control deactivator switch allows for one adjustment. If additional adjustments are
necessary, install a new switch.
1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the
speed control deactivator switch electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and
Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair
Cruise Control Switch: Service and Repair
SPEED CONTROL SWITCH
Removal and Installation
NOTE:
- It is not necessary to remove the driver air bag module during this procedure.
- Be careful not to allow the speed control switch electrical connector to fall back into the steering
wheel.
1. Remove the speed control switch by pulling the switch toward the rear of the vehicle.
- Disconnect the electrical connector.
2. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Locations > Deactivator Switch > Page 9406
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Deactivator Switch
C277
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Diagrams > Deactivator Switch > Page 9409
C278
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 9412
Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS) Brake
Deactivator Switch
BRAKE PEDAL SWITCH (BPS) BRAKE DEACTIVATOR SWITCH
The BPS, also called the brake deactivator switch, is for vehicle speed control deactivation. A
normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is
not applied. When the brake pedal is applied, the normally closed switch opens and power is
removed from the PCM.
On some applications the normally closed BPS, along with the normally open BPP switch, are used
for a brake rationality test within the PCM. The PCM misfire monitor profile learn function may be
disabled if a brake switch concern occurs. If one or both brake pedal inputs to the PCM is not
changing states when they were expected to, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Page 9413
Brake Switch (Cruise Control): Service and Repair
SPEED CONTROL DEACTIVATOR SWITCH
Removal
CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the speed control deactivator switch. Do not install the speed control deactivator switch
without the brake pedal arm secured to the brake booster push rod. Do not pull or push on the
brake pedal when removing or installing the speed control deactivator switch, as misadjustment or
damage to the switch may occur.
1. Disconnect the speed control deactivator switch electrical connector. 2. Rotate counterclockwise
45 degrees and remove the speed control deactivator switch.
Installation
NOTE: When installing the speed control deactivator switch it is automatically self-adjusting to the
proper position. Do not pull up or push down on the pedal during installation. Initial installation of
the speed control deactivator switch allows for one adjustment. If additional adjustments are
necessary, install a new switch.
1. Install the speed control deactivator switch, and rotate clockwise 45 degrees. 2. Connect the
speed control deactivator switch electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Description and Operation
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION (CPP) SWITCH
Typical Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine
load. The PCM uses the load information for mass air flow and fuel calculations.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair
Cruise Control Switch: Service and Repair
SPEED CONTROL SWITCH
Removal and Installation
NOTE:
- It is not necessary to remove the driver air bag module during this procedure.
- Be careful not to allow the speed control switch electrical connector to fall back into the steering
wheel.
1. Remove the speed control switch by pulling the switch toward the rear of the vehicle.
- Disconnect the electrical connector.
2. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Information > Diagrams
C2286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Information > Diagrams > Page 9424
Air Bag Deactivation Indicator: Description and Operation
PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
The passenger air bag deactivation (PAD) indicator is a visual indicator used to inform the front
seat occupants of the passenger air bag deactivation state. The PAD indicator is a stand-alone
lamp installed into the vehicle instrument panel in a position visible to each front seat occupant.
The RCM controls the state of the PAD indicator through a direct hardware connection, based on
information provided by the occupant classification sensor (OCS) system. The PAD indicator is lit
to indicate the passenger air bag module is disabled. An exemption to this is when the front
passenger seat is determined to be empty and passenger safety belt buckle unbuckled, and
therefore indication of a deactivated passenger air bag module is not necessary. In all other cases,
the PAD indicator is unlit when the passenger air bag module is enabled. When the ignition switch
is in the ON position, the PAD indicator prove-out period is initiated by the RCM. The RCM briefly
activates the PAD indicator to prove-out the indicator function and verify to the front occupants
correct functional operation of the PAD indicator.
The PAD indicator will be lit/unlit within 1.0 to 1.5 seconds of a change of state from the OCS
system.
When an OCS system fault is present, the RCM defaults the passenger air bag module to the last
valid state received from the OCS system until the ignition switch is turned OFF. If the OCS system
fault is still present when the ignition switch is turned ON, the RCM defaults the passenger air bag
module to enabled regardless of the size of occupant in the front passenger seat. The PAD
indicator will be unlit.
Passenger Air Bag And PAD Indicator Status
The above table indicates the passenger air bag status and the PAD indicator status based the
size of the front outboard passenger occupant
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Information > Diagrams > Page 9425
Air Bag Deactivation Indicator: Service and Repair
PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR
Removal and 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.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a supplemental
restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
- Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and carry out the diagnostic procedure again.
1. Depower the system. 2. Remove the floor console. 3. Gently pull outward to release the clips on
the instrument panel center finish panel. 4. Disconnect the passenger air bag deactivation (PAD)
indicator electrical connector. 5. Remove the 2 screws and remove the PAD indicator. 6. To install,
reverse the removal procedure. 7. Repower the system.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9430
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9431
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9432
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9433
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9434
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9435
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9436
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9437
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9438
Cigarette Lighter: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9439
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9440
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9441
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9442
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9443
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9444
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9445
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9446
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 9447
Cigarette Lighter: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
44-1
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams
C909
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Vehicle Demagnetizing
Compass: Service and Repair Vehicle Demagnetizing
VEHICLE DEMAGNETIZING
CAUTION: During demagnetizing, the demagnetizer coil pulls 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 4 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. See: Compass Zone Adjustment 3. Carry
out the compass calibration adjustment procedure. See: Compass Calibration
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Vehicle Demagnetizing > Page 9453
Compass: Service and Repair Compass Zone Adjustment
With Message Center
COMPASS ZONE ADJUSTMENT
With Message Center
1. Turn the ignition switch to the ON position. 2. Start the engine. 3. From the SETUP menu, select
compass zone.
4. Determine which magnetic zone you are in for your geographic location. 5. Press the RESET
button until the message center display changes to show the current zone setting. 6. Press the
RESET button repeatedly until the correct zone setting for your geographic location is displayed. 7.
Wait 4 seconds when the correct zone is chosen.
Without Message Center
COMPASS ZONE ADJUSTMENT
Without Message Center
1. Turn the ignition switch to the ON position.
2. Locate the reset button on top of the compass sensor located behind the mirror.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Vehicle Demagnetizing > Page 9454
3. Determine which magnetic zone you are in for your geographic location. 4. Press and hold the
reset button on the compass module for approximately 4 seconds until COMPASS ZONE XX
appears in the instrument
cluster display.
5. Continue to press the reset button until the correct zone setting for your geographic location
appears in the instrument cluster display. 6. After 4 seconds, ZONE SET appears in the instrument
cluster display. The zone is updated.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Service and Repair > Vehicle Demagnetizing > Page 9455
Compass: Service and Repair Compass Calibration
With Message Center
COMPASS CALIBRATION
With Message Center
1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects
or structures. Switch off all non-essential
electrical accessories (rear window defrost, heater, A/C, map lamps, wipers, etc.) and make sure
all doors are closed.
Start the vehicle.
2. From the SETUP menu, press the SETUP button to select the compass calibration function. 3.
Press the RESET button.
4. NOTE:
- It will take up to 5 circles to complete the calibration.
- If not calibrated within 3 minutes or if the RESET button is pressed during CIRCLE SLOWLY TO
CALIBRATE, CIRCLE SLOWLY TO CALIBRATE changes to CAL and the calibration process must
start over.
Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO
CALIBRATE changes to CALIBRATION COMPLETED in the message center.
Without Message Center
COMPASS CALIBRATION
Without Message Center
1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects
or structures. Switch off all non-essential
electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all
doors are closed.
Start the vehicle.
2. Locate the reset button on top of the compass sensor located behind the mirror. 3. Press and
hold the reset button on the compass module for approximately 8 seconds and release.
4. NOTE:
- It will take up to 5 circles to complete the calibration.
- If not calibrated within 3 minutes or if the reset button is pressed during CIRCLE SLOWLY TO
CALIBRATE, CIRCLE SLOWLY TO CALIBRATE changes to CAL and the calibration process must
start over.
Slowly drive the vehicle in a circle at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO
CALIBRATE changes to CALIBRATION COMPLETE in the instrument cluster display.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Special Tool(s)
Special Tool(s)
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box
(SJB), located below the LH side of the instrument panel, remove the cover and the restraints
control module (RCM)
fuse 17 (10A) from the SJB.
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 switch to OFF.
6. WARNING: To avoid accidental deployment and possible personal 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
servicing, 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.
The front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9461
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.
2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the
cover.
4. 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.
5. Prove out the SRS as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9462
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment, which can result in personal injury.
- The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always
wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never
probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in
pretensioner, adaptive load limiting retractor or air bag deployment and could 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 reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9463
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart
junction box (SJB), located below the LH side of the instrument panel, remove the cover and the
restraints control module (RCM)
fuse 17 (10A) from the SJB.
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 front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
7. Remove the 2 driver air bag module bolts (1 shown).
8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation.
Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9464
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
10. Open and lower the glove compartment door.
11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield.
12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive
tether squibs do not require deactivation.
Through the glove compartment opening, disconnect the LH side passenger air bag module
electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector on the LH side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9465
14. From under the rear of the passenger seat, detach the passenger seat side air bag module
electrical connector from the seat track bracket. Then
slide and disengage the passenger seat side air bag module electrical connector locking clip, and
then release the tab and disconnect the passenger seat side air bag module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Vehicles without safety canopy modules
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM.
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Explorer and Mountaineer vehicles with safety canopy modules
17. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9466
18. Disconnect the passenger side safety canopy module electrical connector.
19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
20. Release and position aside the driver side C-pillar trim panel.
21. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9467
22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles with safety canopy modules
23. Remove the driver and passenger side upper C-pillar trim panels.
24. Disconnect the passenger side safety canopy module electrical connector.
25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
26. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9468
27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles
28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module
electrical connector locking clip, and then release
the tab and disconnect the driver seat side air bag module electrical connector.
29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the
battery ground cable.
Reactivation
All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9469
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side
air bag module electrical connector.
4. Connect the driver seat side air bag module electrical connector and then slide and engage the
seat side air bag electrical connector locking clip.
Explorer Sport Trac vehicles with safety canopy modules
5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
6. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9470
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy module electrical connector.
8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and
passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles with safety canopy modules
10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
11. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9471
12. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
side safety canopy module electrical connector.
14. Connect the passenger side safety canopy module electrical connector.
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9472
16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
seat side air bag module electrical connector.
17. Connect the passenger seat side air bag module electrical connector and then slide and
engage the seat side air bag electrical connector locking
clip. Then attach the passenger seat side air bag module electrical connector to the seat track
bracket.
18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector on the LH side.
19. Connect the LH side passenger air bag module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9473
20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21.
Close glove compartment door.
22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the
driver air bag module in the wrong
position. Match the electrical connector key to the keyway in the driver air bag module. Do not force
the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted in removal.
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9474
25. 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.
26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and
install the cover.
28. 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.
29. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch back to ON and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a
scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Locations > Page 9478
C2298
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Locations > Page 9479
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Locations > Page 9480
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Locations > Page 9481
3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front > Page 9486
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front > Page 9487
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Driver Side Front > Page 9488
View 151-25 (Right Rear Door)
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Door Ajar Switch, Driver Side Front
C526
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Door Ajar Switch, Driver Side Front > Page 9491
C602
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Door Ajar Switch, Driver Side Front > Page 9492
C715
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Diagrams > Door Ajar Switch, Driver Side Front > Page 9493
C820
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations
View 151-12 (behind Dash Panel)
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 9497
C253
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Locations > Page 9498
Driver/Vehicle Information Display: Description and Operation
INFORMATION AND MESSAGE CENTER
The message center is a liquid crystal display (LCD), integrated into the instrument cluster. The
message center functions are controlled by the TRIP/RESET button on base instrument clusters,
and by the message center switches on high series instrument clusters. The base series
instrument cluster message center has a display format of 2 lines x 12 characters, and the high
series instrument cluster message center has a display format of 4 lines x 12 characters. The
message center displays important vehicle information by constantly monitoring different vehicle
systems. The message center notifies the driver of a potential vehicle problem by displaying a
warning message pertaining to the system in which a fault has been detected. Refer to the Owner's
Literature for operating instructions.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview
Inspection and Verification
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step.
4. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM.
If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle.
- Check the scan tool connection to the VCM.
- Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to
diagnose no communication with the scan tool.
6. If the scan tool does not communicate with the vehicle:
- Verify the ignition key is in the ON position.
- Verify the scan tool operation with a known good vehicle.
- Refer to Information Bus (Module Communications Network) to diagnose no response from the
powertrain control module (PCM).
7. Carry out the network test:
- If the scan tool responds with no communication for one or more modules, refer to Information
Bus (Module Communications Network).
- If the network test passes, retrieve and record the continuous memory DTCs.
8. Clear the continuous DTCs and carry out the self-test diagnostics for the instrument cluster. 9. If
the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble
Code (DTC) Chart. For all other DTCs, refer to
Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code
Descriptions
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Principles of Operation
PRINCIPLES OF OPERATION
The message center electronic functions use both hardwired inputs and the controller area network
(CAN) to transmit and receive information. It is very important to understand:
- where the input (command) originates.
- all the information (messages) necessary in order for a feature to operate.
- which module(s) receive(s) the input or command message.
- if the module which received the input (message) controls the output of the feature, or if it outputs
a message over the CAN circuit to another module.
- which module controls the output of the feature.
The message center provides the following features:
- Information displays
- Setup displays
- System check messages
- Warning messages
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9501
The message center information can be selected through the TRIP/RESET button (base cluster)
and by the INFO, SETUP, and RESET buttons (high series cluster).
Information Displays (Base Instrument Cluster)
The information displays are non-timed modes. The selected mode remains on until the driver
presses a message center switch to change the mode, or until it is overridden by another mode.
The information display modes are: Odometer/trip odometer, compass headings
- Distance to empty
- Average fuel economy
- Setup menu
Information Displays (High Series Instrument Cluster)
The information displays are non-timed modes. The selected mode remains on until the driver
presses a message center switch to change the mode, or until it is overridden by another mode.
The information display modes are: Odometer/trip odometer, compass headings, outside air temperature display (with dual electronic
automatic temperature control)
- Distance to empty
- Average fuel economy
- Instantaneous fuel economy
- Fuel used
- Trip elapsed drive time
- Blank
Setup Displays (Base Instrument Cluster)
The setup displays are timed modes and terminate after a finite interval. Press the TRIP/RESET
button to scroll through the SETUP MENU display sequence. If the TRIP/RESET button is not
pressed within 4 seconds, the message center returns to the INFO MENU. The setup display
modes are: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only)
- System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Parking aid
- Oil life start value
Setup Displays (High Series Instrument Cluster)
The setup displays are timed modes and terminate after a finite interval. Press the SETUP button
for the following displays: AWD lock (vehicles equipped with traction control with roll stability control [RSC] only)
- System check
- Units (English/metric)
- Language
- Autolamp
- Autolock
- Auto-unlock
- Running boards (if equipped)
- Easy entry/exit seat
- Parking aid
- Compass zone
- Compass calibration
- Oil life start value
System Check Displays
Selecting this function from the SETUP MENU causes the message center to cycle through each of
the systems being monitored. For each of the monitored systems, the message center indicates
either an OK message or a warning message for 2 seconds. For base instrument clusters, the
TRIP/RESET button must be held down after pressing the TRIP/RESET button to cycle the
messages through each of the systems being monitored. For high series instrument clusters,
pressing the RESET control switch cycles the message center through each of the systems being
monitored. The system check report is as follows: OIL LIFE RESET
- CHARGING SYSTEM
- WASHER FLUID
- DOOR AJAR
- EXTERIOR LAMPS
- BRAKE FLUID LEVEL
- PARK BRAKE
- FUEL LEVEL
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9502
System Warnings
The system warnings alert the operator to possible problems or malfunctions in the vehicle
operating systems. The message center displays the last selected feature if there are no more
warning messages. This allows the operator full functionality of the message center after
acknowledgement of the warning message by pressing the RESET button and clearing the
message. The warning messages are divided into 4 categories: They cannot be cleared until the condition is corrected.
- They reappear on the display 10 minutes from the reset if the condition has not been corrected.
- They do not reappear until an ignition OFF-ON cycle has been completed.
- They reappear if the condition clears then reoccurs within the same ignition ON-OFF cycle.
The warning displays that cannot be reset are: DOOR AJAR
- CLEAR OBJECTS BY PASS SEAT
The warning messages that reoccur after 10 minutes are: CHECK CHARGING SYSTEM
- FUEL LEVEL LOW
- PARK BRAKE ENGAGED
- CHECK BRAKE SYSTEM
The warning messages that display whenever the ignition switch is turned from the OFF position to
the ON position are: CHECK PARK AID
- BRAKE FLUID LEVEL LOW
- CHECK HEADLAMP
- CHECK HIGHBEAM
- CHECK TURN LAMP
- WASHER FLUID LOW LEVEL
- OIL CHANGE REQUIRED
- ENGINE OIL CHANGE SOON
The warning messages that return after a condition has cleared then reoccurs within the same
ignition ON-OFF cycle are: LIFTGATE/GLASS AJAR
- LOW TIRE PRESSURE
- TIRE MONITOR FAULT
- TIRE SENSOR FAULT
- TRAIN TIRES
- TIRES TRAINED
- TIRES NOT TRAINED
Outside Air Temperature Sensor (Base Instrument Cluster without Electronic Automatic
Temperature Control [EATC])
The base instrument cluster receives the outside air temperature data from the outside air
temperature sensor. This data is then displayed on the message center. The outside air
temperature sensor is located on the radiator core support behind the front grill assembly and is
fastened with a pin-type retainer. If equipped with a high series instrument cluster, the outside air
temperature data from the outside air temperature sensor is displayed in the electronic automatic
temperature control (EATC) module.
Compass
The compass heading is displayed as one of N, NE, E, SE, S, SW, W and NW in the message
center display. The compass reading may be affected when you drive near large buildings, bridges,
power lines and powerful broadcast antenna. Magnetic or metallic objects placed in, on or near the
vehicle may also affect compass accuracy. The compass sensor module is mounted behind the
interior rear view mirror.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9503
B1255-B2097 / U2013
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9504
Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9505
Symptom Chart (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9506
Symptom Chart (Part 3)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9507
Symptom Chart (Part 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9508
Symptom Chart (Part 5)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9509
Driver/Vehicle Information Display: Pinpoint Tests
Test A: The Message Center Is Not Operating Correctly
PINPOINT TEST A: THE MESSAGE CENTER IS NOT OPERATING CORRECTLY (HIGH
SERIES INSTRUMENT CLUSTER)
A1
A2
Normal Operation
The message center functionality is controlled through the message center switch, which is
hardwired to the instrument cluster through circuits CMC29 (GN/VT) and RMC32 (GN/BU).
Possible Causes
- Message center switch
- Instrument cluster
Test B: The Compass Is Inoperative
PINPOINT TEST B: THE COMPASS IS INOPERATIVE.
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9510
B1
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9511
B2-B3
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9512
B4
Normal Operation
The compass sensor module receives voltage from the smart junction box (SJB) through circuit
CBP18 (GY/OG) and is grounded through circuit GD143 (BK/VT). The compass sensor module
communicates the vehicle direction to the instrument cluster, which is displayed in the message
center. The compass sensor module uses circuits VMC30 (BU/GY) and VMC31 (YE/GN) to
communicate to the instrument cluster.
DTC B2097 - is a continuous memory DTC that sets in the instrument cluster if the data received
from the compass module is invalid.
DTC U2013 - is a continuous and on-demand DTC that sets if the instrument cluster fails to receive
a response from the compass module after 4 consecutive attempts.
Possible Causes
- Fuse
- Circuit CBP18 (GY/OG) open
- Circuit GD143 (BK/VT) open
- Circuit VMC30 (BU/GY) open or short to ground
- Circuit VMC31 (YE/GN) open or short to ground
-- Compass sensor module
Test C: The Compass Is Inaccurate
PINPOINT TEST C: THE COMPASS IS INACCURATE
C1-C2
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9513
C2
Normal Operation
The compass sensor module communicates the vehicle direction to the instrument cluster to
display in the message center.
Possible Causes
- Compass out of calibration
- Zone setting
- Vehicle is magnetized
- Compass sensor module
Test D: The Message Center Switch Does Not Operate Correctly
PINPOINT TEST D: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY
(HIGH SERIES INSTRUMENT CLUSTER)
D1-D2
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9514
D2-D4
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9515
D4-D5
Normal Operation
The message center switch uses circuit CMC29 (GN/VT) to communicate the requested switch
function to the instrument cluster message center. The message center switch is grounded through
circuit RMC32 (GN/BU). Each message center switch uses a different resistance value allowing the
instrument cluster to determine which switch is pressed.
Possible Causes
- Circuit CMC29 (GN/VT) open, short to ground or voltage
- Circuit RMC32 (GN/BU) open
- Message center switch
- Instrument cluster
Test E: The Outside Air Temperature Display Does Not Operate Correctly
PINPOINT TEST E: THE OUTSIDE AIR TEMPERATURE DISPLAY DOES NOT OPERATE
CORRECTLY
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9516
E1-E3
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9517
E3-E5
NOTE: The outside air temperature display is only available in base instrument clusters without
electronic automatic temperature control (EATC).
Normal Operation
The outside air temperature sensor is hardwired to the instrument cluster through circuits VH407
(YE/GN) and RMC32 (GN/BU). The message center displays the outside air temperature upon
receipt of the outside air temperature data.
DTC B1255 - is a continuous and on-demand DTC that sets if the instrument cluster detects an
open on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument cluster
detects an open on the outside air temperature input, the instrument cluster defaults the display to
23.5° Celsius (75°F).
DTC B1257 - is a continuous and on-demand DTC that sets if the instrument cluster detects a short
to ground on the outside air temperature sensor input circuit VH407 (YE/GN). If the instrument
cluster detects a short to ground on the outside air temperature input, the instrument cluster
defaults
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9518
the display to 23.5°Celsius (75°F).
Possible Causes
- Circuit VH407 (YE/GN) open or short to ground
- Circuit RMC32 (GN/BU) open
- Ambient air temperature sensor
- Instrument cluster
Test F: The Washer Fluid Low Level Warning Is Inoperative
PINPOINT TEST F: THE WASHER FLUID LOW LEVEL WARNING IS INOPERATIVE
F1-F2
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Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9519
F3-F6
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9520
F6-F7
Normal Operation
The instrument cluster is hardwired to the low washer fluid switch (part of the windshield washer
reservoir) through circuit CMC20 (VT). The low washer fluid switch closes when the washer fluid
level is approximately 1/3 full, providing a ground to the instrument cluster through circuit GD108
(BK/VT) and turning on the WASHER FLUID LOW LEVEL warning. When the washer fluid is above
the low level, the low washer fluid switch opens, removing the ground to the instrument cluster, and
the WASHER FLUID LOW LEVEL warning turns off.
Possible Causes
- Circuit GD108 (BK/VT) open
- Circuit CMC20 (VT) open or short to ground
- Washer fluid level switch (part of the windshield washer reservoir)
- Instrument cluster
Test G: The Check Charging System Warning Is Inoperative
PINPOINT TEST G: THE CHECK CHARGING SYSTEM WARNING IS INOPERATIVE
G1-G2
Normal Operation
The charging system warning indicator is controlled by the instrument cluster based upon data
received from the powertrain control module (PCM)
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9521
over the high speed controller area network (HS-CAN).
Possible Causes
- Charging system
- Instrument cluster
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Procedures
Driver/Vehicle Information Display: Procedures
Message Center Cluster
OIL LIFE RESET - MESSAGE CENTER CLUSTER
NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days.
1. Press and release the SETUP button until the message center displays PRESS RESET TO
BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center
displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and
release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET.
Base Instrument Cluster
OIL LIFE RESET - BASE INSTRUMENT CLUSTER
NOTE: Oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days.
1. Press and release the TRIP/RESET button until the message center displays SETUP MENU
HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center
displays RESET FOR SYSTEM CHECK. 3. Press and hold the TRIP/RESET button for 2 seconds
until the message center displays OIL LIFE xx% RESET IF NEW. 4. Press and release the
TRIP/RESET button until the message center displays HOLD RESET IF NEW OIL. 5. Press and
hold the TRIP/RESET button for 2 seconds and release to reset the oil life to 100%. 6. Message
center briefly displays OIL CHANGE SET TO 100%.
Message Center Cluster
OIL LIFE START VALUE - MESSAGE CENTER CLUSTER
NOTE: The oil life start value is used to reset the oil life value back to the maximum of
approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value
from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%.
1. Press and release the SETUP button until the message center displays OIL LIFE START
VALUE SET TO XX%. 2. Press and release the RESET button to lower the percentage by 10%
(down to 10%) for each button press or return the value to 100%.
Base Instrument Cluster
OIL LIFE START VALUE - BASE INSTRUMENT CLUSTER
NOTE: The oil life start value is used to reset the oil life value back to the maximum of
approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value
from the maximum (8,000 km [5,000 miles]) in 10% increments down to 10%.
1. Press and release the TRIP/RESET button until the message center displays SETUP MENU
HOLD RESET. 2. Press and hold the TRIP/RESET button for 2 seconds until the message center
displays RESET FOR SYSTEM CHECK. 3. Press and release the TRIP/RESET button until the
message center displays OIL LIFE SET TO XX%. 4. Press and hold the TRIP/RESET button for 2
seconds to lower the percentage by 10% (down to 10%) for each button press-and-hold or return
the
value to 100%.
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Procedures > Page 9524
Driver/Vehicle Information Display: Removal and Replacement
MESSAGE CENTER SWITCH
Removal and Installation
1. Remove the instrument panel center finish panel.
2. Press the retaining tabs and remove the message center switch. 3. To install, reverse the
removal procedure.
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Special Tool(s)
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp >
Component Information > Diagrams
C2260
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Distance/Mileage Module: > 09-21-7 >
Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9537
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distance/Mileage Module: >
09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9543
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator >
Component Information > Description and Operation
Fuel Filler Cap Warning Indicator: Description and Operation
CHECK FUEL CAP INDICATOR
The check fuel cap indicator is a communications network message sent by the PCM. The PCM
sends the message to illuminate the lamp when the strategy determines that there is a failure in the
vapor management system due to the fuel filler cap not being sealed correctly. This would be
detected by the inability to pull vacuum in the fuel tank, after a fueling event.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions
Fuel Gauge: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9551
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9552
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9553
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9554
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9555
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9556
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9557
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9558
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9559
Fuel Gauge: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9560
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9561
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9562
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9563
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9564
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9565
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9566
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 9567
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation
Fuel Gauge Sender: Description and Operation
FUEL PUMP (FP) MODULE
Typical Electronic Returnless Fuel Pump (FP) Module
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9571
Typical Mechanical Returnless Fuel Pump (FP) Module
The FP module 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.
FUEL PUMP (FP) MODULE AND RESERVOIR
The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check
valve that maintains the system pressure after the key has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9572
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9573
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9574
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9575
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9576
All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9577
4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Page 9578
4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEPOWERING AND REPOWERING
Special Tool(s)
Special Tool(s)
Depowering Procedure
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the electrical connector on a safety canopy module. Doing so can result in safety
canopy deployment.
- Do not handle, move or change the original horizontal mounting position of the restraints control
module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these
instructions may result in the inadvertent deployment of the safety canopy and risk of personal
injury.
- To reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
- The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is
ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box
(SJB), located below the LH side of the instrument panel, remove the cover and the restraints
control module (RCM)
fuse 17 (10A) from the SJB.
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 switch to OFF.
6. WARNING: To avoid accidental deployment and possible personal 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
servicing, 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.
The front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
Repowering Procedure
1. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove
from vehicle prior to road use. Failure to
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9584
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.
2. Turn the ignition switch from OFF to ON. 3. Install RCM fuse 17 (10A) to the SJB and close the
cover.
4. 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.
5. Prove out the SRS as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator
will light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is
present, the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous diagnostic trouble codes (DTCs) from the RCM and occupant classification
sensor (OCS) module using a scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9585
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Deactivation and Reactivation
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION
Special Tool(s)
Special Tool(s)
Deactivation
WARNING:
- Always wear safety glasses when repairing an air bag supplemental restraint system (SRS)
vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an
accidental deployment.
- Carry a live air bag module with the air bag and trim cover pointed away from your body. This will
reduce the risk of injury in the event of an accidental deployment.
- Do not set a live air bag module down with the trim cover face down. This will reduce the risk of
injury in the event of an accidental deployment.
- After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the
gas generant combustion that is irritating to the skin. Wash your hands with soap and water
afterwards.
- Never probe the connectors on the air bag module. Doing so can result in air bag deployment,
which can result in personal injury.
- Never probe the connectors on the safety canopy module. Doing so can result in safety canopy
deployment, which can result in personal injury.
- The safety belt pretensioner and adaptive load limiting retractor are pyrotechnic devices. Always
wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt
buckle pretensioner or safety belt retractor pretensioner/adaptive load limiting retractor. Never
probe a pretensioner or adaptive load limiting retractor electrical connector. Doing so could result in
pretensioner, adaptive load limiting retractor or air bag deployment and could 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 reduce the risk of personal injury, do not use any memory saver devices.
NOTE:
- If a seat equipped with a SRS component is being serviced, the SRS must be depowered.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9586
- The air bag warning lamp illuminates when the restraints control module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a SRS fault.
- The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart
junction box (SJB), located below the LH side of the instrument panel, remove the cover and the
restraints control module (RCM)
fuse 17 (10A) from the SJB.
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 front impact severity sensors are located on the radiator support bracket above the lower front
splash shield.
The front door side impact sensors are located in the first row doors, behind the door trim panel.
The C-pillar side impact sensors (if equipped) are located on the C-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.
7. Remove the 2 driver air bag module bolts (1 shown).
8. NOTE: Note the position of the 3 driver air bag module wiring connectors for installation.
Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9587
9. Attach the restraint system diagnostic tools to the clockspring electrical connectors at the top of
the steering column.
10. Open and lower the glove compartment door.
11. Detach the wiring retainer, remove the 4 bolts and the passenger air bag module heat shield.
12. NOTE: Deactivate the passenger air bag module as shown, the canister vent and adaptive
tether squibs do not require deactivation.
Through the glove compartment opening, disconnect the LH side passenger air bag module
electrical connector.
13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag
module electrical connector on the LH side.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9588
14. From under the rear of the passenger seat, detach the passenger seat side air bag module
electrical connector from the seat track bracket. Then
slide and disengage the passenger seat side air bag module electrical connector locking clip, and
then release the tab and disconnect the passenger seat side air bag module electrical connector.
15. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat
side air bag module electrical connector.
Vehicles without safety canopy modules
16. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy
bridge resistor from the safety canopy
electrical connector.
If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the RCM.
If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low
resistance fault will be generated by the RCM.
Explorer and Mountaineer vehicles with safety canopy modules
17. Release and position aside the passenger side C-pillar trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9589
18. Disconnect the passenger side safety canopy module electrical connector.
19. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
20. Release and position aside the driver side C-pillar trim panel.
21. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9590
22. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
Explorer Sport Trac vehicles with safety canopy modules
23. Remove the driver and passenger side upper C-pillar trim panels.
24. Disconnect the passenger side safety canopy module electrical connector.
25. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side
safety canopy module electrical connector.
26. Disconnect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9591
27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety
canopy module electrical connector.
All vehicles
28. From under the rear of the driver seat, slide and disengage the driver seat side air bag module
electrical connector locking clip, and then release
the tab and disconnect the driver seat side air bag module electrical connector.
29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air
bag module electrical connector. 30. Install the RCM fuse 17 (10A) to the SJB. 31. Connect the
battery ground cable.
Reactivation
All vehicles 1. Remove the RCM fuse 17 (10A) from the SJB. 2. Disconnect the battery ground
cable and wait at least one minute.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9592
3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side
air bag module electrical connector.
4. Connect the driver seat side air bag module electrical connector and then slide and engage the
seat side air bag electrical connector locking clip.
Explorer Sport Trac vehicles with safety canopy modules
5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
6. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9593
7. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side
safety canopy module electrical connector.
8. Connect the passenger side safety canopy module electrical connector. 9. Install the driver and
passenger upper C-pillar trim panels.
Explorer and Mountaineer vehicles with safety canopy modules
10. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side
safety canopy module electrical connector.
11. Connect the driver side safety canopy module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9594
12. Install the driver side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
side safety canopy module electrical connector.
14. Connect the passenger side safety canopy module electrical connector.
15. Install the passenger side C-pillar trim panel.
- Verify the safety belt retractor operates without excessive effort or binding.
All vehicles
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9595
16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger
seat side air bag module electrical connector.
17. Connect the passenger seat side air bag module electrical connector and then slide and
engage the seat side air bag electrical connector locking
clip. Then attach the passenger seat side air bag module electrical connector to the seat track
bracket.
18. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air
bag module electrical connector on the LH side.
19. Connect the LH side passenger air bag module electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9596
20. Install the passenger air bag module heat shield and the 4 bolts. Attach the wiring retainer. 21.
Close glove compartment door.
22. Remove the restraint system diagnostic tools from the clockspring electrical connectors at the
top of the steering column.
23. CAUTION: The clockspring electrical connectors are unique and cannot be connected to the
driver air bag module in the wrong
position. Match the electrical connector key to the keyway in the driver air bag module. Do not force
the electrical connectors into the driver air bag module.
Connect the driver air bag module electrical connectors as noted in removal.
24. Install the 2 driver air bag module bolts (1 shown).
- Tighten to 7 Nm (62 lb-in).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering > Page 9597
25. 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.
26. Turn the ignition switch from OFF to ON. 27. Install the RCM fuse 17 (10A) to the SJB and
install the cover.
28. 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.
29. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the switch back to ON and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag indicator will: fail to light.
- remain lit continuously.
- flash at a 5 Hz rate (RCM not configured).
The air bag indicator might not light 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 RCM to complete the
testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound
in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered
must be diagnosed and repaired.
Clear all continuous DTCs from the RCM and occupant classification sensor (OCS) module using a
scan tool.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb
Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb
INSTRUMENT CLUSTER BULB
1. Remove the instrument cluster.
2. NOTE: To remove the illumination bulb, rotate the bulb one quarter turn counterclockwise and lift
out from the instrument cluster.
Remove the illumination bulb(s).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Component Information > Service and Repair > Instrument Cluster Bulb > Page 9602
Instrument Panel Bulb: Service and Repair Warning Indicator Bulb
WARNING INDICATOR BULB
Removal and Installation
1. Remove the instrument cluster.
2. NOTE: To remove a warning indicator bulb, rotate the bulb one quarter turn counterclockwise
and lift it out from the instrument cluster.
Remove the warning indicator bulb(s) in question.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9611
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip
Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9617
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component
Information > Testing and Inspection
Low Tire Pressure Indicator: Testing and Inspection
TPMS Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that
cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced.
TPMS Indicator Illuminates Continuously
NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the
vehicle to restore complete TPMS functionality before carrying out any diagnosis.
1. The TPMS indicator remains on continuously for this condition:
^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays
LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low.
When this condition exists, the tire pressure must be adjusted to the recommended cold pressure
as indicated on the vehicle certification label.
2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been
stationary for more than 30 minutes, it will be
necessary to wake up the sensors so they will transmit the latest tire pressure information to the
SJB.
If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the
TPMS sensors. 1
Turn the ignition switch to the ON position.
2 Adjust the air pressure in the LF tire.
3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool.
4 Repeat Steps 2 and 3 for the remaining tires.
5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to
Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic
Procedures
TPMS Indicator Flashes
The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is
turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the
message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning.
GO to Symptom Chart. See: Tire Monitoring System/Testing and Inspection/Symptom Related
Diagnostic Procedures
2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is
illuminated when the instrument cluster has received no
signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
MONITOR FAULT. GO to Symptom Chart. See: Tire Monitoring System/Testing and
Inspection/Symptom Related Diagnostic Procedures
3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR
FAULT when the tire pressure monitoring system is
malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart.
See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 MIL notifies the driver that the powertrain control module (PCM) has detected an on board
diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD
diagnostic trouble code (DTC) sets.
- The MIL is located in the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or the international standards organization (ISO) standard engine symbol.
- The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
- The MIL remains illuminated after instrument cluster prove out if: an emission-related concern and DTC exists.
- the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
- the PCM is operating in the hardware limited operation strategy (HLOS).
- The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster
concern is present.
- To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3
consecutive drive cycles must be completed without a concern.
- For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures
- If the MIL flashes at a steady rate, a severe misfire condition may exist.
- If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low.
- The MIL flashes after a period of time with the key in the RUN position (engine not running) if
DTC P1000 is set.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display
Moves On Screen
Odometer: Customer Interest Instruments - Odometer Display Moves On Screen
TSB 10-2-15
02/15/10
ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF
MESSAGE CENTER SCREEN
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit a condition where the odometer display reading momentarily flips from the bottom to the top
of the message center screen, then back to the normal display mode (Figure 1). This concern may
be very intermittent and difficult to verify.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one
required) which must be ordered directly from the supplier Newark listed below:
^ Newark telephone number 1-800-463-9275.
^ Newark website: www.Newark.com.
^ Newark part number: 78K6137.
^ Manufacturer: Fair Rite.
^ Manufacturer part number: 0444176451.
1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01.
NOTE
IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display
Moves On Screen > Page 9632
2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits.
(Figure 3)
3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer Display
Moves On Screen > Page 9633
4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5)
5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the
instrument cluster bracket. (Figure 6)
6. Install the IC. Refer to WSM, Section 413-01.
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
100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install
Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any
Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel
Economy Resets
Odometer: Customer Interest Instruments - Trip Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Customer Interest for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel
Economy Resets > Page 9638
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer
Display Moves On Screen
Odometer: All Technical Service Bulletins Instruments - Odometer Display Moves On Screen
TSB 10-2-15
02/15/10
ODOMETER DISPLAY READING MOMENTARILY FLIPS FROM BOTTOM TO TOP OF
MESSAGE CENTER SCREEN
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit a condition where the odometer display reading momentarily flips from the bottom to the top
of the message center screen, then back to the normal display mode (Figure 1). This concern may
be very intermittent and difficult to verify.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
The following procedure involves installing a Fair Rite Round Cable Snap-On Suppressor (only one
required) which must be ordered directly from the supplier Newark listed below:
^ Newark telephone number 1-800-463-9275.
^ Newark website: www.Newark.com.
^ Newark part number: 78K6137.
^ Manufacturer: Fair Rite.
^ Manufacturer part number: 0444176451.
1. Remove the Instrument Cluster (IC). Refer to the Workshop Manual (WSM), Section 413-01.
NOTE
IT IS NOT NECESSARY TO DOWNLOAD THE IC CONFIGURATION INFORMATION.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer
Display Moves On Screen > Page 9644
2. Install the Fair Rite Round Cable Snap-On Suppressor around the cluster harness circuits.
(Figure 3)
3. Install PVC tape (164-R4901) from Rotunda kit (164-R4900) around the suppressor. (Figure 4)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 10-2-15 > Feb > 10 > Instruments - Odometer
Display Moves On Screen > Page 9645
4. Install a tie strap in between the Suppressor and the wiring harness. (Figure 5)
5. Tuck the suppressor behind the IC plastic support bracket and secure the tie strap around the
instrument cluster bracket. (Figure 6)
6. Install the IC. Refer to WSM, Section 413-01.
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
100215A 2006-2010 Explorer, 0.7 Hr. Mountaineer 2007-2010 Explorer Sport Trac: Install
Suppressor, Includes Time To Remove And Install The Instrument Cluster (Do Not Use With Any
Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 42
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip
Odometers/Fuel Economy Resets
Odometer: All Technical Service Bulletins Instruments - Trip Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Odometer: > 09-21-7 > Nov > 09 > Instruments - Trip
Odometers/Fuel Economy Resets > Page 9650
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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
Message Center Configuration Oil Life Reset - Message Center Cluster
NOTE:The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days
1. Press and release the SETUP button until the message center displays PRESS RESET TO
BEGIN SYSTEM CHECK. 2. Press and release the RESET button until the message center
displays HOLD RESET IF NEW OIL. 3. Press and hold the RESET button for 2 seconds and
release to reset the oil life to 100%. 4. The message center displays SETUP MENU HOLD RESET.
Oil Life Reset - Base Instrument Cluster
NOTE: The oil life calculation is set at a maximum of approximately 8,000 km (5,000 miles) or 180
days.
1. Place the ignition in the RUN position with the engine off (KOEO). 2. Press and release the
TRIP/RESET button until SETUP MENU HOLD RESET is displayed. 3. Press and hold the
TRIP/RESET button until SYSTEM CHECK is displayed. 4. Release the TRIP/RESET button. 5.
Press and release the TRIP/RESET button to scroll through the system check menu items until
HOLD RESET IF NEW OIL is displayed. 6. Press and hold the TRIP/RESET button until OIL LIFE
SET TO 100% is displayed. 7. Release the TRIP/RESET button. The oil life is now reset.
Oil Life Start Value - Message Center Cluster
NOTE:The oil life start value is used to reset the oil life value back to the maximum of
approximately 8,000 km (5,000 miles) if the value was previously changed or to lower the value
from the maximum (8,000 km
To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000
km) or 180 days] perform the following:
1. Enter SYSTEM CHECK to display "OIL XXX% OIL LIFE OK". 2. Press RESET control to display
"HOLD RESET IF NEW OIL". 3. Press and hold RESET control for more than 2 seconds. Oil life is
set to 100% and "OIL CHANGE SET TO 100%" is displayed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
View 151-7 (Engine, Front - 4.6L)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations > Page 9657
C103
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Diagrams
C3268
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Diagrams
C2015
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel
Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Customer Interest for Fuel
Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9673
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Fuel Distance/Mileage Module: All Technical Service Bulletins Instruments - Trip Odometers/Fuel
Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Fuel Distance/Mileage Module: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9679
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: Customer Interest Instruments - Trip Odometers/Fuel Economy
Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 9688
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Trip
Odometers/Fuel Economy Resets
TSB 09-21-7
11/02/09
TRIP A/TRIP B ODOMETER AND/OR AVERAGE FUEL ECONOMY RESETS
UNINTENTIONALLY
FORD: 2006-2010 Explorer 2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer
ISSUE Some 2006-2010 Explorer, Mountaineer and 2007-2010 Explorer Sport Trac vehicles may
exhibit the trip odometer (Trip A or Trip B) or the Average Fuel Economy resetting unintentionally.
This condition may occur if there is an intermittent electrical connection on the power feed to the
cluster or if the reset button on the 3-button message center assembly is momentarily touched.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. With the key in the On position, display the trip odometer mileage.
2. Start the vehicle.
3. Cycle the key back Off and restart the vehicle.
4. Verify whether the trip mileage reset or not.
5. If not, proceed to Step 10.
6. If it reset, turn the key Off and remove the key from the ignition.
7. Activate the emergency flashers.
8. If the flashers do not function in the cluster (exterior lights perform as expected), perform normal
fuse and wiring diagnostics to correct the power
feed circuit.
9. Verify repair and proceed to Step 10.
10. Reprogram the Instrument Cluster Module (ICM) to the latest calibration using IDS release
63.07 and higher. This new calibration is not included
in the VCM 2009.9 DVD. Calibration files may also be obtained at the website.
NOTE
REPLACING THE CLUSTER OR THE 3-BUTTON MESSAGE CENTER ASSEMBLY WILL NOT
RESOLVE THIS ISSUE.
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
092107A 2006-2010 Explorer, 0.3 Hr.
Mountaineer 2007-2010 Explorer Sport Trac: Reprogram The ICM, Includes Time To Verify If The
Trip Odometer Reset (For Additional Repairs Use SLTS Operations If Available; Claim Additional
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page
9694
Diagnosis Or Labor Performed As Actual Time)
DEALER CODING
CONDITION
BASIC PART NO. CODE
10849 04
Disclaimer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Description and Operation
Seat Belt Reminder Lamp: Description and Operation
Safety Belt Warning Indicator And Chime
The warning indicator and chime are reminders to fasten the safety belt. The system operates as
follows: If the driver safety belt is not buckled before the ignition switch is turned to the RUN or START
position, the indicator will illuminate for 1-2 minutes and the chime will sound for 4-8 seconds.
- If the driver safety belt is buckled while the indicator is on and the chime is sounding, both the
indicator and chime will turn off.
- If the safety belt is buckled before the ignition is turned to the ON position, neither the indicator
nor the chime will turn on.
Belt Minder
The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature
provides an additional reminder that the driver's and/or front passenger's safety belt is unbuckled
by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument
cluster.
To activate or deactivate the Belt Minder feature, refer to Seat Belt Systems or the owner's
literature.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Locations > Page 9702
C2298
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Locations > Page 9703
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Locations > Page 9704
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Locations > Page 9705
3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9710
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9711
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 9712
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Door Ajar Switch, Driver Side Front
C526
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 9715
C602
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 9716
C715
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 9717
C820
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation
Fuel Gauge Sender: Description and Operation
FUEL PUMP (FP) MODULE
Typical Electronic Returnless Fuel Pump (FP) Module
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9721
Typical Mechanical Returnless Fuel Pump (FP) Module
The FP module 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.
FUEL PUMP (FP) MODULE AND RESERVOIR
The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check
valve that maintains the system pressure after the key has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9722
Fuel Gauge Sender: Service and Repair
FUEL LEVEL SENSOR
Explorer Sport Trac (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9723
Explorer Sport Trac (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9724
Explorer/Mountaineer (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9725
Explorer/Mountaineer (Part 2)
All Vehicles (Part 1)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9726
All Vehicles (Part 2)
Removal
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.
1. Remove the fuel pump.
2. NOTE: Note the routing of the sending unit wire for installation.
Remove the heat shrink tube covering the electrical connector.
3. Disconnect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9727
4. Remove the screw and lift up to remove the fuel gauge sending unit.
Installation
1. Route the fuel gauge sending unit wire through the center of the fuel pump module.
2. NOTE:
- Both fuel gauge sending wires must be routed behind the metal sending unit plate.
- The grounding eyelet must be on the front side of the sending unit.
Hook the fuel gauge sending unit on the fuel pump module and install the screw through the
grounding eyelet and tighten the screw.
3. Slide the heat shrink tube onto the wire harness and connect the electrical connector.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Description and Operation > Page 9728
4. WARNING: Do not use an open flame to shrink the heat shrink tube, use a heat gun only.
Failure to follow these instructions may result
in personal injury.
Using a heat gun, shrink the heat shrink tube.
5. Install the fuel pump.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Diagrams
C2015
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Testing and Inspection
Low Tire Pressure Indicator: Testing and Inspection
TPMS Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that
cannot be resolved by the customer. Treat these messages as TPMS faults that must be serviced.
TPMS Indicator Illuminates Continuously
NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the
vehicle to restore complete TPMS functionality before carrying out any diagnosis.
1. The TPMS indicator remains on continuously for this condition:
^ Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays
LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are low.
When this condition exists, the tire pressure must be adjusted to the recommended cold pressure
as indicated on the vehicle certification label.
2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been
stationary for more than 30 minutes, it will be
necessary to wake up the sensors so they will transmit the latest tire pressure information to the
SJB.
If the vehicle has been stationary for more than 30 minutes, carry out this procedure to wake up the
TPMS sensors. 1
Turn the ignition switch to the ON position.
2 Adjust the air pressure in the LF tire.
3 Activate the LF TPMS sensor, at least 2 times, using the tire pressure monitor activation tool.
4 Repeat Steps 2 and 3 for the remaining tires.
5 If the TPMS indicator remains illuminated after adjusting and activating each sensor, GO to
Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures
TPMS Indicator Flashes
The TPMS indicator flashes for 70 seconds and then remains ON solid when the ignition key is
turned to the ON position for these conditions: 1. Tire Pressure Sensor Fault - If equipped, the
message center will display TIRE SENSOR FAULT when a tire pressure sensor is malfunctioning.
GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures
2. No communication with the SJB (TPMS is integral to the SJB) - The TPMS indicator is
illuminated when the instrument cluster has received no
signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE
MONITOR FAULT. GO to Symptom Chart. See: Testing and Inspection/Symptom Related
Diagnostic Procedures
3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE MONITOR
FAULT when the tire pressure monitoring system is
malfunctioning or communication with the instrument cluster has been lost. GO to Symptom Chart.
See: Testing and Inspection/Symptom Related Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Testing and Inspection
Tire Pressure Sensor: Testing and Inspection
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Smart Junction Box (SJB).
NOTE: The tire pressure sensor training procedure must be done on a single vehicle, in an area
without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to
activate the same sensor with the Tire Pressure Monitor Activation Tool. If the sensor still does not
respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate
the same sensor again.
NOTE: The SJB has a 2-minute time limit between sensor responses. If the SJB does not
recognize any 1 of the 4 tire pressure sensors during this time limit, the horn will sound twice and
the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire
procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain
F-Series), the tire pressure sensors must be trained following a tire rotation. Failure to train the
sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for
front and rear tires, tire rotation will not affect the system.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal. 2. Cycle the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position. 3.
Press and release the brake pedal. 4. Turn the ignition switch to the OFF position. 5. Turn the
ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully. If equipped, the message center will display TRAIN LF TIRE.
NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place 180 degrees from the valve stem.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Testing and Inspection > Page 9739
6. Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees)
from the valve stem. Press and release the test
button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the
tire pressure sensor has been recognized by the SJB.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall opposite (180 degrees) from the
valve stem and press and release the test button to train the RF tire pressure sensor.
NOTE: Do not wait more than 2 minutes between training each sensor or the SJB will time out and
the entire procedure must be repeated.
8. Repeat Step 7 for the RR and LR tires.
The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE. For vehicles
not equipped with a message center, successful completion of the training procedure will be
verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and
document them on the applicable warranty claim.
NOTE: This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed SJB.
10. If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry
out the SJB On-Demand Self Test.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor can be removed and installed without removing the strap or the cradle.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Dismount the tire only as
instructed.
Remove the tire from the wheel.
2. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor locking clip can occur.
Using a pocket screwdriver, or similar tool, remove the sensor locking clip.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9742
3. CAUTION: Do not use a large screwdriver. Apply minimum force during removal or damage to
the sensor can occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle.
4. Remove the sensor.
Assembly
1. CAUTION: Damage to the sensor can occur if excessive force is applied during sensor
installation.
NOTE: Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise
when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the
cradle and pushing the opposite end of the sensor down onto the cradle.
2. NOTE: The locking clip can only be fully seated when installed in the correct orientation. If the
sensor locking clip cannot be fully inserted, then
the sensor may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9743
3. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
4. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9744
Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and
Cradle
Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9745
Disassembly
CAUTION: Tire pressure sensors are manufactured in multiple colors based on their application.
When installing a new sensor, make sure the color of the sensor being installed matches the color
of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE: The sensor is available separately, the cradle and strap are available as a strap kit. There
are several different strap kits available based on wheel diameter but all strap kits share the same
base part number.
NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of
accordingly.
1. Remove the tire pressure monitoring system (TPMS) sensor.
2. WARNING: The TPMS band is under tension. Always use safety goggles or a face shield and
gloves when removing the TPMS
band/strap. Failure to follow these instructions may result in personal injury.
Remove a factory installed strap in this sequence: 1
Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item, on both
sides of the buckle approximately 25 mm (0.98 inch) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap. To remove a dealer installed strap, turn the worm gear screw until the strap is
fully released from the worm gear.
^ Discard the strap.
3. NOTE: To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle
and prying up.
Assembly
1. NOTE: Make sure the sensor is fully seated into the new cradle. The sensor will make a "click"
noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end
of the cradle and pushing the opposite end of the sensor down onto the cradle.
2. CAUTION: Metal scrapers can damage the wheel. Use only plastic or non-metallic scrapers to
remove the cradle adhesive strip residue.
NOTE: The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the
valve stem.
Clean the area where the sensor and cradle are to be installed.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9746
3. NOTE: The sensor and cradle must be positioned with the hinge side of the sensor on the RH
side when viewed from the curb side (beauty side)
of the wheel.
NOTE: The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel
drop well 180° from the valve stem.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the
sensor. This will position the worm gear on the
locking clip side of the sensor.
5. CAUTION: Steel wheels have a "high spot" along their circumference. Make sure the strap is
positioned in the lowest spot possible for
correct sensor and cradle retention.
NOTE: Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13 - 26 mm (0.5 - 1.0 inch) away from the sensor and tighten the worm
gear. ^
Tighten to 3 Nm (27 inch lbs.)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Sensor > Component Information > Service and Repair > Tire Pressure Monitoring System (TPMS) Sensor > Page 9747
6. CAUTION: The sensor, cradle and strap can be damaged by incorrect tire mounting or
dismounting. Mount the tire only as instructed.
Install the tire onto the wheel.
7. NOTE: A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must
be turned on before it can be trained. To turn the
sensor on, install it on a wheel, mount the tire and inflate the tire to the recommended inflation
pressure. Wait at least 2 minutes, then continue with the sensor training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T >
Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9755
C286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 9756
Ambient Light Sensor: Service and Repair
LIGHT SENSOR
Removal and Installation
1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove
the upper center instrument panel finish panel.
- Disconnect the electrical connector.
3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Diagrams
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9765
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9766
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9767
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9768
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9769
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9770
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9771
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9772
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9773
Brake Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9774
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9775
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9776
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9777
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9778
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9779
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9780
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9781
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9782
Brake Lamp: Connector Views
C4032
C4035
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9783
Brake Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
90-1
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9784
90-2
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Brake Lamp: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern.
Visual Inspection Chart
2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for
an observed or reported concern is found, correct the cause (if possible) before proceeding to the
next step.
NOTE:
- Make sure the headlamp switch is in the OFF position.
- Make sure the multifunction switch is in the LOW BEAM position.
4. NOTE: Make sure to use the latest scan tool release software.
If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
5. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM.
If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle.
- Check the scan tool connection to the VCM.
- Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to
diagnose no communication with the scan tool.
6. If the scan tool does not communicate with the vehicle:
- Verify the ignition key is in the ON position.
- Verify the scan tool operation with a known good vehicle.
- Refer to Information Bus (Module Communications Network) to diagnose no response from the
powertrain control module (PCM).
7. Carry out the network test.
- If the scan tool responds with no communication with the SJB, refer to Information Bus (Module
Communications Network).
- If the network test passes, retrieve and record the continuous memory DTCs.
8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB. 9. If the DTCs
retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code
(DTC) Chart. For all other DTCs,
refer to Information Bus (Module Communications Network). See: Diagnostic Trouble Code
Descriptions
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9787
B2048-B2051 / C1446-C1788
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9788
Symptom Chart
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9789
Brake Lamp: Pinpoint Tests
Test H: The Stoplamps Are Inoperative
PINPOINT TEST H: THE STOPLAMPS ARE INOPERATIVE
H1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9790
H1-H3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9791
H4-H5
Normal Operation
The stoplamp switch is supplied voltage through circuit SBP22 (BN/RD) from the smart junction
box (SJB). When the brake pedal is applied, the stoplamp switch routes voltage to the SJB through
circuit CCB08 (VT/WH).
Possible Causes
- Fuse
- Circuit CCB08 (VT/WH) open
- Circuit SBP22 (BN/RD) open
- Stoplamp switch
- SJB
Test I: One or More Stoplamps Are Inoperative
PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9792
I1-I2
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9793
I2-I3
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9794
I3-I4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9795
I5-I7
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9796
I8-I9
Normal Operation - All Vehicles
When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box
(SJB). The voltage is then routed out of the SJB to the high mounted stoplamp through circuit
CCB08 (VT/WH).
Normal Operation - Explorer
When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear
stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the high
mounted stoplamp and the LH rear stoplamp is provided through circuit GD149 (BK/GY). Ground
for the RH rear stoplamp is provided through circuit GD151 (BK/GN).
Normal Operation - Explorer Sport Trac
When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear
stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively. Ground for the high
mounted stoplamp is provided through circuit GD133 (BK). Ground for the LH and RH rear
stoplamps is provided through circuit GD148 (BK/YE).
Normal Operation - Mountaineer
When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear
stoplamps through circuit CLS44 (VT/BN). Ground for the high mounted stoplamp and the LH rear
stoplamp is provided through circuit GD149 (BK/GY). Ground for the RH rear stoplamp is provided
through circuit GD151 (BK/GN).
DTC B2048 - is a continuous and on-demand DTC that sets when the SJB detects a short to
ground from the LH rear turn lamp voltage supply circuit. The self-test must be run after the repair
in order for the SJB to enable the output for the LH rear turn lamp voltage supply.
DTC B2049 - is a continuous and on-demand DTC that sets when the SJB detects an open or
short to voltage from the LH rear turn lamp voltage supply circuit.
DTC B2050 - is a continuous and on-demand DTC that sets when the SJB detects a short to
ground from the RH rear turn lamp voltage supply circuit. The self-test must be run after the repair
in order for the SJB to enable the output for the RH rear turn lamp voltage supply.
DTC B2051 - is a continuous and on-demand DTC that sets when the SJB detects an open or
short to voltage from the RH rear turn lamp voltage supply circuit.
DTC C1788 - is a continuous and on-demand DTC that sets when the SJB detects a short to
ground from the rear stoplamp voltage supply circuit. The self-test must be run after the repair in
order for the SJB to enable the output for the rear stoplamp voltage supply.
Possible Causes
- Fuse
- Circuit CCB08 (VT/WH) open
- Circuit CLS18 (GY/BN) open or short to ground
- Circuit CLS19 (VT/OG) open or short to ground
- Circuit CLS44 (VT/BN) open or short to ground
- Circuit GD133 (BK) open
- Circuit GD148 (BK/YE) open
- Circuit GD149 (BK/GY) open
- Circuit GD151 (BK/GN) open
- High mounted stoplamp
- Light emitting diode (LED) module
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9797
- SJB.
Test J: The Stoplamps Are On Continuously
PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY
J1
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9798
J2-J9
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9799
J10-J14
Normal Operation - All Vehicles
When the brake pedal is applied, the stoplamp switch routes voltage to the smart junction box
(SJB), the brake shift interlock actuator, the trailer electric brake controller, the four wheel drive
(4WD) control module, the anti-lock brake system (ABS) module, and the powertrain control
module (PCM) through circuit CCB08 (VT/WH). The voltage is then routed out of the SJB to the
high mounted stoplamp through circuit CCB08 (VT/WH).
Normal Operation - Explorer, Explorer Sport Trac
When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear
stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG), respectively.
Normal Operation - Mountaineer
When the SJB detects the brake pedal applied, the SJB provides voltage to the LH and RH rear
stoplamps through circuit CLS44 (VT/BN).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 9800
DTC B1446 - is an on-demand DTC that sets when the SJB detects a short to voltage from the
brake pedal applied input circuit.
Possible Causes
- Circuit CCB08 (VT/WH) short to voltage
- Circuit CLS18 (GY/BN) short to voltage
- Circuit CLS19 (VT/OG) short to voltage
- Circuit CLS44 (VT/BN) short to voltage
- Stoplamp switch - Brake shift interlock actuator
- Trailer electric brake controller
- SJB
- 4WD control module
- ABS module
- PCM
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Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page
9801
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9805
C278
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Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9806
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9807
Brake Light Switch: Service and Repair
STOPLAMP SWITCH
Removal and Installation
CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm
secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or
installing the stoplamp switch, as misadjustment or damage to the switch may occur.
1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees
clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams
C927
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door
Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Removal and Installation
1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3.
Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 9816
Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Removal and Installation
1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch
counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 9817
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Removal and Installation
1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch
counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp Switch > Component Information >
Service and Repair > Door Ajar Switch - Front Door > Page 9818
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Removal and Installation
1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and
remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams
C254
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Daytime Running Lamp: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
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Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9826
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
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Information and Instructions > Page 9827
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
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Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9828
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
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Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9829
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
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Information and Instructions > Page 9830
Symbols Part 2
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Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9831
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9832
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9833
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9834
Daytime Running Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9835
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9836
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9837
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9838
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9839
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9840
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9841
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9842
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9843
Daytime Running Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
97-1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9844
97-2
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Page
9845
Daytime Running Lamp: Description and Operation
DAYTIME RUNNING LAMPS (DRL)
NOTE: The smart junction box (SJB) must be configured when installing a new module.
The DRL system operates the low beam headlamps at a reduced intensity. The SJB supplies pulse
width modulated (PWM) voltage to illuminate the low beam headlamps at a reduced intensity when
the following conditions are met:
- The headlamp switch is not in the HEADLAMPS ON position.
- The ignition switch is in the RUN position.
- The transmission is not in PARK (P).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Inspection and Verification
Daytime Running Lamp: Testing and Inspection Inspection and Verification
INSPECTION AND VERIFICATION
NOTE: When installing a new smart junction box (SJB), it must be configured for this feature, if
originally equipped. Refer to Information Bus (Module Communications Network).
1. Verify the customer concern by operating the daytime running lamps (DRL) following these
steps:
- Place the ignition switch in the RUN position.
- Place the headlamp switch in the OFF position.
- Place the transmission in any gear other than PARK (P).
- If the DRL does not operate, make sure the SJB is configured for DRL before proceeding to the
next step.
2. Verify the low beam operation.
- Place the headlamp switch in the HEADLAMPS ON position. If the low beams do not operate correctly, refer to Headlamps for correct diagnosis.
- If the low beams operate correctly and the DRL operation is incorrect, proceed to the next step.
3. Check the SJB inputs.
- Monitor the ignition switch PIDs and the transmission gear status PIDs. If the ignition switch PIDs do not agree with the ignition switch position, refer to Ignition Switch to
continue diagnosis of the ignition switch.
- If the transmission gear status PIDs do not agree with the gear selector lever position, refer to
Transmission Control Systems. or Transmission Control Systems to continue diagnosis of the
transmission.
- If the PIDs indicate correct ignition and transmission gear status, install a new SJB. Refer to Body
Control Systems (Multifunction Electronic Control Module). Test the system for normal operation.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Inspection and Verification > Page 9848
Daytime Running Lamp: Testing and Inspection Principles of Operation
PRINCIPLES OF OPERATION
NOTE: When installing a new smart junction box (SJB), it must be configured for this feature, if
originally equipped. Refer to Information Bus (Module Communications Network).
The SJB controls the DRL by using various inputs to determine whether or not the DRL should be
illuminated. These inputs include:
- Ignition switch position
- Headlamp switch position
- Headlamps on or off
- Transmission gear selection
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection
> Page 9849
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 9853
C2298
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 9854
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 9855
Dimmer Switch: Service and Repair
INSTRUMENT PANEL DIMMER SWITCH
Removal and Installation
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations > Page 9856
3. Release the 2 tabs and remove the instrument panel dimmer switch. 4. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front
Dome Lamp: Service and Repair Interior Lamp - Front
INTERIOR LAMP - FRONT
Removal and Installation
1. NOTE: Use a small screwdriver to pry open the garage door opener bin.
Open the rear overhead console storage or garage door opener bin to access the retaining screw. Remove the screw.
2. Pull the front of the overhead console down and remove the console from the console retaining
clips.
- Disconnect the electrical connector(s).
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front > Page 9861
Dome Lamp: Service and Repair Interior Lamp - Rear
INTERIOR LAMP - REAR
Removal and Installation
1. Remove the rear interior lamp lens.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior
Lamp - Front > Page 9862
2. Release the 2 retaining clips (through the access holes) and remove the rear interior lamp
assembly.
- Disconnect the electrical connector.
3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front > Page 9867
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front > Page 9868
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch,
Driver Side Front > Page 9869
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch,
Driver Side Front
C526
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch,
Driver Side Front > Page 9872
C602
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch,
Driver Side Front > Page 9873
C715
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch,
Driver Side Front > Page 9874
C820
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information >
Service and Repair
Fog/Driving Lamp Bulb: Service and Repair
FOG LAMP BULB
Removal and Installation
WARNING: The fog lamp bulb contains gas under pressure. The bulb may shatter if the glass
envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the
glass envelope. Failure to follow these instructions may result in personal injury.
NOTE:
- The fog lamp bulb should not be removed from the fog lamp assembly until just before a new bulb
is installed. Removing the bulb for an extended period of time may affect fog lamp bulb
performance. Contaminants may enter the fog lamp assembly where they can settle on the lens
and reflector. Never turn on the fog lamps with the bulb removed from the fog lamp assembly.
- Make sure the headlamp switch and ignition switch are in the OFF position.
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the electrical connector and
remove the fog lamp bulb. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 9882
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Application and ID
Hazard Warning Flasher: Application and ID
The flasher function for this vehicle is provided by the Smart Junction Box (SJB).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
HEADLAMP BULB
Explorer, Explorer Sport Trac
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair > Page 9891
Mountaineer
Removal and Installation
WARNING: The headlamp bulb contains gas under pressure. The bulb may shatter if the glass
envelope is scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the
glass envelope. Failure to follow these instructions may result in personal injury.
NOTE: The headlamp bulb should not be removed from the headlamp assembly 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 assembly where they can settle on the lens
and reflector. Never turn on the headlamps with the bulb removed from the headlamp assembly.
1. Remove the headlamp assembly. 2. Rotate the headlamp bulb one-eighth turn counterclockwise
and remove the headlamp bulb. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 9895
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 9896
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 9897
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations > Page 9898
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 9902
C205
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 9903
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 9904
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
Removal and Installation
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions
License Plate Lamp: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9913
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9914
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9915
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9916
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9917
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9918
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9919
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9920
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9921
License Plate Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9922
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9923
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9924
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9925
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9926
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9927
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9928
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9929
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9930
License Plate Lamp: Connector Views
C452
C462
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9931
License Plate Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
92-1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 9932
92-2
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9937
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9938
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9939
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9940
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9941
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9942
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9943
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9944
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9945
Marker Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9946
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9947
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9948
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9949
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9950
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9951
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9952
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9953
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9954
Marker Lamp: Connector Views
C1127
C1126
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9955
Marker Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
92-1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 9956
92-2
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 9957
Marker Lamp: Service and Repair
SIDE MARKER LAMP
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the socket from the side marker
lamp. 3. Remove the 2 nuts and the side marker lamp. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
> Page 9962
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 9967
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Page 9971
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations > Page 9975
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 9980
C286
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 9981
Ambient Light Sensor: Service and Repair
LIGHT SENSOR
Removal and Installation
1. Position the top portion of the lower center instrument panel finish panel rearward. 2. Remove
the upper center instrument panel finish panel.
- Disconnect the electrical connector.
3. Remove the 2 screws and the light sensor. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Diagrams
C167
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
View 151-16 (Left Front)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 9988
C278
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 9989
Brake Light Switch: Description and Operation
BRAKE PEDAL POSITION (BPP) SWITCH
Typical BPP Switch
The BPP switch is sometimes referred to stoplamp switch. The BPP switch provides a signal to the
PCM indicating that the brakes are applied. The BPP switch is normally open and is mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows:
- to the PCM supplying battery positive voltage (B+) when the vehicle brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ABS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 9990
Brake Light Switch: Service and Repair
STOPLAMP SWITCH
Removal and Installation
CAUTION: Do not remove or repair the brake pedal, brake booster or master cylinder without first
removing the stoplamp switch. Do not install the stoplamp switch without the brake pedal arm
secured to the brake booster push rod. Do not pull or push on the brake pedal when removing or
installing the stoplamp switch, as misadjustment or damage to the switch may occur.
1. Disconnect the stoplamp switch electrical connector. 2. Rotate the stoplamp switch 45 degrees
clockwise and remove the stoplamp switch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door
Console Lamp Switch: Service and Repair Door Ajar Switch - Front Door
DOOR AJAR SWITCH - FRONT DOOR
Removal and Installation
1. Remove the front door latch. 2. Disconnect the front door ajar switch electrical connector. 3.
Release the locking tab and rotate the front door ajar switch counterclockwise and remove the
switch from the front door latch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9995
Console Lamp Switch: Service and Repair Door Ajar Switch - Rear Door
DOOR AJAR SWITCH - REAR DOOR
Removal and Installation
1. Remove the rear door latch. 2. Release the locking tab, rotate the rear door ajar switch
counterclockwise and remove the switch from the rear door latch. 3. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9996
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate
DOOR AJAR SWITCH - LIFTGATE
Removal and Installation
1. Remove the liftgate latch. 2. Release the locking tab, rotate the liftgate ajar switch
counterclockwise and remove the ajar switch form the liftgate latch. 3. To install, reverse the
removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Console Lamp Switch >
Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 9997
Console Lamp Switch: Service and Repair Door Ajar Switch - Liftgate Glass
DOOR AJAR SWITCH - LIFTGATE GLASS
Removal and Installation
1. Remove the liftgate window latch. 2. Rotate the liftgate window ajar switch counterclockwise and
remove the ajar switch from the liftgate window latch. 3. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 10002
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 10003
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Driver Side Front > Page 10004
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front
C526
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 10007
C602
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 10008
C715
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Diagrams > Door Ajar Switch, Driver Side Front > Page 10009
C820
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10013
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10014
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10015
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations > Page 10016
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
View 151-12 (behind Dash Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10020
C205
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10021
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations > Page 10022
Headlamp Switch: Service and Repair
HEADLAMP SWITCH
Removal and Installation
1. Remove the driver side register. 2. Remove the headlamp switch and bezel as an assembly.
- Disconnect the electrical connectors.
3. Remove the 3 screws and the headlamp switch. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Locations
View 151-14 (Steering Wheel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10029
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10030
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10031
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 10032
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10037
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10038
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10039
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10040
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10041
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10042
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10043
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10044
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10045
Tail Lamp: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10046
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10047
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10048
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10049
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10050
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10051
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10052
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10053
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10054
Tail Lamp: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
92-1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 10055
92-2
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions
Trailer Lamps: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10060
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10061
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10062
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10063
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10064
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10065
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10066
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10067
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10068
Trailer Lamps: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10069
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10070
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10071
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10072
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10073
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10074
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10075
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10076
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10077
Trailer Lamps: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
95-1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10078
95-2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information
and Instructions > Page 10079
95-3
Diagrams: Other diagrams referred to by number (See Diagram ##-#, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Component Location Views. See: Diagrams/Components/Component Location
Views
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
INSPECTION AND VERIFICATION
1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating
correctly. If not, refer to the appropriate pinpoint test. 3. Visually inspect the following for obvious
signs of electrical damage.
VISUAL INSPECTION CHART
Electrical Battery junction box (BJB) fuse(s): 13 (30A) (trailer tow battery charge relay - switched)
- 17 (30A) (trailer brake control module)
- Smart junction box (SJB) fuse(s): 7 (15A) (trailer stop/turn lamps)
- 12 (5A) (trailer tow battery charge relay coil)
- 16 (10A) (trailer reversing lamps)
- 25 (15A) (trailer parking lamps and trailer brake control module)
- SJB
- Circuity
- Trailer
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
NOTE:
- Make sure the headlamp switch is in the OFF position.
- Make sure the multifunction switch is in the LOW BEAM position.
5. NOTE: Make sure to use the latest scan tool release software.
If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
6. NOTE: The vehicle communication module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM.
If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle.
- Check the scan tool connection to the VCM.
- Refer to Information Bus (Module Communications Network), No Power To The Scan Tool, to
diagnose no communication with the scan tool.
7. If the scan tool does not communicate with the vehicle:
- Verify the ignition key is in the ON position.
- Verify the scan tool operation with a known good vehicle.
- Refer to Information Bus (Module Communications Network) to diagnose no response from the
powertrain control module (PCM).
8. Carry out the network test.
- If the scan tool responds with no communication with the SJB, refer to Information Bus (Module
Communications Network).
- If the network test passes, retrieve and record the continuous memory DTCs.
9. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB.
10. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic
Trouble Code (DTC) Chart. For all other DTCs,
refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble
Code Descriptions
11. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are
all functioning correctly with the trailer disconnected.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10082
B2070
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10083
Trailer Lamps: Symptom Related Diagnostic Procedures
Symptom Chart (Part 1)
Symptom Chart (Part 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10084
Trailer Lamps: Pinpoint Tests
Test V: The Trailer Lamps Are Inoperative - Trailer Parking Lamps
PINPOINT TEST V: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER PARKING LAMPS
V1-V2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10085
V2-V3
Normal Operation
Voltage to the trailer parking lamps is supplied by the smart junction box (SJB) through circuit
CAT17 (BN).
Possible Causes
- Fuse
- Circuit CAT17 (BN) open
- Trailer
- SJB
Test W: The Trailer Lamps Are Inoperative - Trailer Reversing Lamps
PINPOINT TEST W: THE TRAILER LAMPS ARE INOPERATIVE - TRAILER REVERSING LAMPS
W1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10086
W1-W3
Normal Operation
Voltage to the trailer reversing lamps is supplied by the smart junction box (SJB) through circuit
CAT16 (GY/BN).
Possible Causes
- Fuse
- Circuit CAT16 (GY/BN) open
- Trailer
- SJB
Test X: The Individual Trailer Lamp Is Inoperative - LH Trailer Stoplamp
PINPOINT TEST X: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH TRAILER
STOPLAMP
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10087
X1-X2
X3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10088
Normal Operation
Voltage to the LH trailer stoplamp is supplied by the smart junction box (SJB) through circuit
CAT06 (YE).
DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the LH
trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the
SJB to enable the output for the LH trailer turn/stoplamp voltage supply.
Possible Causes
- Circuit CAT06 (YE) open or short to ground
- Trailer
- SJB
Test Y: The Individual Trailer Lamp Is Inoperative - RH Trailer Stoplamp
PINPOINT TEST Y: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH TRAILER
STOPLAMP
Y1-Y2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10089
Y2-Y3
Normal Operation
Voltage to the RH trailer stoplamp is supplied by the smart junction box (SJB) through circuit
CAT09 (GN).
DTC B2070 - is a continuous DTC that sets when the SJB detects a short to ground from the RH
trailer turn/stoplamp voltage supply circuit. The self-test must be run after the repair in order for the
SJB to enable the output for the RH trailer turn/stoplamp voltage supply.
Possible Causes
- Circuit CAT09 (GN) open or short to ground
- Trailer
- SJB
Test Z: The Trailer Lamps Are On Continuously
PINPOINT TEST Z: THE TRAILER LAMPS ARE ON CONTINUOUSLY
Z1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10090
Z1-Z3
Normal Operation
Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits CAT06 (YE)
and CAT09 (GN) supply voltage to the trailer tow LH and RH stoplamps, respectively.
Possible Causes
- Circuit CAT06 (YE) short to voltage
- Circuit CAT09 (GN) short to voltage
- Trailer
- SJB
Tests AA: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly
PINPOINT TEST AA: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT
OPERATE CORRECTLY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10091
AA1-AA3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10092
AA3-AA4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10093
AA4-AA5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10094
AA5 Continued
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10095
AA6-AA8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10096
AA8-AA10
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10097
AA10-AA11
Normal Operation
The trailer battery charge relay coil receives voltage from the smart junction box (SJB) fuse 12 (5A)
through circuit CBP12 (GN/WH) when the ignition switch is in the RUN or ACC position. Ground for
the trailer battery charge relay coil is supplied through circuit GD120 (BK/GN). The battery junction
box (BJB) fuse 13 (30A) supplies voltage to the trailer battery charge relay through circuit SSB13
(GY/RD). When the trailer battery charge relay is energized, the voltage is routed to the trailer tow
connector through circuit CAT14 (OG).
Possible Causes
- Fuse
- Circuit CAT14 (OG) open or short to voltage
- Circuit CBP12 (GN/WH) open or short to voltage
- Circuit GD120 (BK/GN) open
- Circuit SSB13 (GY/RD) open
- Trailer battery charge relay
- Trailer
- SJB
Tests AB: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly
PINPOINT TEST AB: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT
OPERATE CORRECTLY
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10098
AB1-AB2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10099
AB3-AB5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10100
AB6-AB8
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 10101
AB9
Normal Operation
The trailer electric brake controller is provided voltage at all times by the battery junction box (BJB)
fuse 17 (30A) through circuit SBB17 (RD). Ground for the trailer electric brake controller is provided
through circuit GD138 (BK/WH). The trailer electric brake controller receives voltage from the
stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested,
the trailer electric brake controller provides voltage to the trailer tow connector through circuit
CAT19 (BU).
Possible Causes
- Fuse
- Circuit CAT17 (BN) open
- Circuit CAT19 (BU) open, short to ground, or short to voltage
- Circuit CCB08 (VT/WH) open
- Circuit GD138 (BK/WH) open
- Circuit SBB17 (RD) open
- Trailer electric brake controller
- Trailer
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Page
10102
Special Tool(s)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 10106
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Application
and ID
Turn Signal Flasher: Application and ID
The flasher function for this vehicle is provided by the Smart Junction Box (SJB).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp
Turn Signal Lamp: Diagrams Park/Turn Lamp
C1023
C1043
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp > Page 10115
C4032
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Park/Turn Lamp > Page 10116
C4035
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10120
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10121
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10122
Turn Signal Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 10123
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left
C907
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp,
Left > Page 10128
C906
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Rear Window Defrost Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Rear Window Defrost Relay > Page 10135
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Testing and Inspection > Rear Window Defrost Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Testing and Inspection > Rear Window Defrost Relay > Page 10138
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Rear Window Defrost Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Rear Window Defrost Relay > Page 10144
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Testing and Inspection > Rear Window Defrost Relay
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Testing and Inspection > Rear Window Defrost Relay > Page 10147
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 10153
Power Window Switch: Locations Window Adjust Switch
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 10154
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 10155
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Rear Window Adjust Switch > Page 10156
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch
C980
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 10159
Power Window Switch: Diagrams Master Window Adjust Switch
C504A
C504B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 10160
Power Window Switch: Diagrams Window Adjust Switch
C604
C701
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Rear Window Adjust Switch > Page 10161
C801
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Adjust Switch
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 10164
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
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 10165
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 10166
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
Removal and Installation
1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release
the clips. 3. Disconnect the window control switch electrical connectors from the window control
switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair
Front Door Window Motor: Service and Repair
WINDOW REGULATOR MOTOR - FRONT DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Page 10172
Part 2
Exploded View
Removal and Installation
1. Remove the front door window regulator. 2. Remove the 3 front door window regulator motor
bolts.
- To install, tighten to 7 Nm (62 lb-in).
3. Remove the front door window regulator motor. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair
Rear Door Window Motor: Service and Repair
WINDOW REGULATOR MOTOR - REAR DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Service and Repair > Page 10176
Part 2
Exploded View
Removal and Installation
1. Remove the interior moulding. 2. Remove the rear door trim panel and weather shield. 3.
Remove the 3 window regulator motor bolts.
- To install, tighten to 7 Nm (62 lb-in).
4. Remove the window regulator motor. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Rear Window Adjust Switch
View 151-26 (Roof)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Rear Window Adjust Switch > Page 10181
Power Window Switch: Locations Window Adjust Switch
View 151-25 (Right Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Rear Window Adjust Switch > Page 10182
View 151-24 (Left Rear Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Rear Window Adjust Switch > Page 10183
View 151-23 (Passenger Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Rear Window Adjust Switch > Page 10184
View 151-22 (Driver Door)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch
C980
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch > Page 10187
Power Window Switch: Diagrams Master Window Adjust Switch
C504A
C504B
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch > Page 10188
Power Window Switch: Diagrams Window Adjust Switch
C604
C701
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Rear Window Adjust Switch > Page 10189
C801
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 10192
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Adjust Switch > Page 10193
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 10194
Power Window Switch: Service and Repair
WINDOW CONTROL SWITCH
Removal and Installation
1. Remove the interior door handle cover. 2. Lift the window control switch bezel upward to release
the clips. 3. Disconnect the window control switch electrical connectors from the window control
switch. 4. Disconnect the window control switch from the window control switch bezel to remove. 5.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed
Back Window Glass: Service and Repair Window Glass - Rear, Fixed
WINDOW GLASS - REAR, FIXED
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed > Page 10200
Part 2
Exploded View
Removal and Installation
1. Remove the cab rear panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed > Page 10201
2. Remove the 15 rear window glass mounting nuts.
- To install, tighten to 3 Nm (27 lb-in).
3. Remove the rear window glass. 4. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed > Page 10202
Back Window Glass: Service and Repair Window Glass - Rear, Power
WINDOW GLASS - REAR, POWER
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed > Page 10203
Part 2
Exploded View
Removal and Installation
1. Remove the rear window glass regulator.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Information > Service and Repair > Window Glass - Rear, Fixed > Page 10204
2. Remove both C-pillar upper trim panels. 3. Remove the 12 rear window glass mounting nuts.
- To install, tighten to 3 Nm (27 lb-in).
4. Remove the rear window glass. 5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door
Window Glass Weatherstrip > Component Information > Service and Repair
Front Door Window Glass Weatherstrip: Service and Repair
DOOR GLASS TOP RUN - FRONT
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door
Window Glass Weatherstrip > Component Information > Service and Repair > Page 10209
Part 2
Exploded Views
Removal and Installation
1. Remove the front door window glass. 2. Remove the exterior moulding. 3. Remove the front door
glass top run channel assembly bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Remove the front door glass top run channel assembly through the top opening of the front door.
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair
Liftgate Window Glass: Service and Repair
WINDOW GLASS - LIFTGATE
Material
Material
Removal and Installation
1. If installing a new liftgate window glass, remove the rear window wiper motor. 2. Position the
liftgate trim panel aside to access the liftgate window glass electrical connectors and the 2 liftgate
window glass hinge-to-glass screws. 3. Disconnect the liftgate window glass electrical connectors.
4. CAUTION: Open and support the liftgate window glass before removing the liftgate window glass
struts.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair > Page 10213
Remove the liftgate window glass struts. To avoid breaking the liftgate window glass, disconnect the liftgate window glass struts from the
liftgate window glass before disconnecting the liftgate window glass struts from the rear liftgate.
5. Remove the 2 liftgate hinge-to-glass screws.
- Apply threadlock into the liftgate window glass hinge-to-glass bolt hole, making sure that the
threadlock is on the threads.
- To install, tighten to 10 Nm (89 lb-in).
6. With the help of an assistant, remove the liftgate window glass. 7. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair
Quarter Window Glass: Service and Repair
WINDOW GLASS - REAR QUARTER
Special Tool(s)
Special Tool(s)
Material
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 10217
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. Failure to follow these instructions may
result in personal injury.
1. Remove the rear quarter trim panel. 2. Remove the wiring harness brackets.
3. NOTE: Locating tabs need to be cut through in order to remove the rear quarter window glass.
The new rear quarter window glass will be
equipped with new locating tabs.
Lubricate the urethane adhesive with water to aid the special tool when cutting.
4. Using the special tool, cut the urethane adhesive from the rear quarter window glass starting at
the top center, working toward the bottom corners
to remove the rear quarter glass.
5. Using a soft brush or vacuum, remove any foreign material or dirt from the pinchweld.
Installation
CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the
urethane adhesive has cured. Refer to the drive away chart time for the cure time as temperatures
and humidity vary. Inadequate curing of the urethane adhesive will adversely affect the strength of
the urethane bond.
1. Dry fit the rear quarter window glass, making alignment marks with tape or non-staining grease
pencil.
2. NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch
weld, see manufacturer's recommendations.
Using an appropriate tool, trim the urethane adhesive leaving a 1-mm to 2-mm base of original
equipment urethane on the pinch weld.
3. Clean the inside of the rear quarter glass encapsulation rim surface with glass cleaner, making
sure the area is clean.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Page 10218
4. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer.
Do not mix different brands of urethane
and primer. Refer to the Material Chart in this procedure.
NOTE: Sika uses the same black primer for the glass and pinch weld area.
If installing a new rear quarter window glass, apply urethane glass primer according to
manufacturer's instructions. Allow at least 6 minutes to dry.
5. Cut the urethane adhesive applicator tip to specification.
6. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane
with less effort and continuous bead.
Use caution when applying urethane adhesive. Apply to the outside edges of the locating tabs on
the glass surface. Start at the bottom and work around to the sides of the rear quarter window
glass.
7. Install the rear quarter window glass, aligning it to the marks previously made. 8. Install the
wiring harness brackets. 9. Install the rear quarter trim panel.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door
Window Glass Weatherstrip > Component Information > Service and Repair
Rear Door Window Glass Weatherstrip: Service and Repair
DOOR GLASS TOP RUN - REAR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door
Window Glass Weatherstrip > Component Information > Service and Repair > Page 10223
Part 2
Exploded View
Removal and Installation
1. Remove the rear door window glass. 2. Remove the exterior moulding. 3. Remove the rear door
glass top run assembly bolt.
- To install, tighten to 12 Nm (9 lb-ft).
4. Remove the rear door glass top run channel assembly.
- Remove the rear door glass top run channel assembly through the top opening of the rear door.
5. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair
Front Door Window Regulator: Service and Repair
WINDOW REGULATOR - FRONT DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 10228
Part 2
Exploded View
Removal and Installation
1. Remove the front door trim panel. 2. Remove the front door speaker. 3. Remove the exterior
mirror front door weather shield. 4. Disconnect the exterior mirror electrical connector.
5. Release the 3 door wiring harness pin-type retainers. 6. Remove the front door weather shield.
7. Remove the door trim panel reinforcement screw. 8. Remove the door trim panel reinforcement.
9. CAUTION: Make sure the holes in the glass bracket do not become enlarged during the rivet
removal process. If the holes become
enlarged, the new rivets may become loose, resulting in a clicking noise concern.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
Remove the 2 front door window glass-to-regulator rivets. Position the front door window glass as necessary to access the front door window
glass-to-regulator rivets.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Page 10229
10. Secure the front door glass in the full up position with tape. 11. Disconnect the window
regulator motor electrical connector. 12. Remove the 5 window regulator assembly nuts.
- To install, tighten to 10 Nm (89 lb-in).
13. Remove the window regulator assembly. 14. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair
Rear Door Window Regulator: Service and Repair
WINDOW REGULATOR - REAR DOOR
Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Service and Repair > Page 10233
Part 2
Exploded View
Removal and Installation
1. Remove the rear door trim panel. 2. Remove the rear door speaker. 3. Remove the interior
moulding. 4. Remove the rear door weather shield.
5. CAUTION: Make sure the hole in the glass bracket does not become enlarged during the rivet
removal process. If the hole becomes
enlarged, the new rivet may become loose, resulting in a clicking noise concern.
NOTE: Use a 4.5 mm (0.1772 in) drill bit to drill out the glass-to-regulator rivets.
Remove the rear door window glass-to-regulator rivet. Position the rear door window glass as necessary to access the rear door window
glass-to-regulator rivet.
6. Secure the rear door window glass in the full up position with tape. 7. Disconnect the window
regulator motor electrical connector. 8. Remove the 2 window regulator nuts.
- To install, tighten to 10 Nm (89 lb-in).
9. Remove the 3 window regulator motor bracket nuts.
- To install, tighten to 10 Nm (89 lb-in).
10. Remove the window regulator assembly. 11. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
Windshield: Procedures
WINDSHIELD RESEAL
Material
Material
1. Remove the RH and LH side A-pillar trim panel. 2. Remove the sun visors, retainers and, if
equipped, the overhead console. 3. If equipped, remove the roof opening panel trim. 4. Remove
the interior mirror. 5
Lower the front portion of the headliner.
6. Remove the wiper pivot arms. 7. Remove the cowl panel grille. 8. Clean the edge formed by the
existing urethane and the glass on the inside at the top, sides and outside on the bottom of the
windshield with glass
cleaner.
9. Cut the urethane applicator tip to specification.
10. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane
with less effort and a continuous bead.
Apply a bead of urethane adhesive to the cleaned area.
11. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous
bead.
Backfill the urethane application and clean the excess.
12. CAUTION: The urethane adhesive must cure for a minimum of one hour before testing for air or
water leaks.
After the urethane has cured, check the windshield seal for air or water leaks through the urethane
adhesive bead and add urethane adhesive as necessary.
13. Install the cowl panel grille. 14. Install the wiper pivot arms. 15. Raise the headliner and
position. 16. If equipped, install the roof opening panel trim. 17. Install the interior mirror. 18. Install
the sun visors, retainers and, if equipped, the overhead console.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 10238
19. Install the RH and LH side A-pillar trim panels. 20. Clean the exterior and interior of the
windshield glass with glass cleaner.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 10239
Windshield: Removal and Replacement
WINDSHIELD GLASS
Special Tool(s)
Special Tool(s)
Material
Material
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 10240
Removal
WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses
and heavy gloves when cutting and removing the glass from the vehicle.
1. Remove the RH and LH side A-pillar trim panels. 2. Remove the sun visors and retainers and, if
equipped, the overhead console. 3. If equipped, remove the roof opening panel trim. 4. Remove
the interior mirror. 5. Lower the front portion of the headliner. 6. Remove the wiper pivot arms. 7.
Remove the cowl panel grille.
8. NOTE: LH shown, RH similar.
If equipped, disconnect the heated windshield electrical connectors. Disconnect the connector.
- Remove the connector from the retainer.
- Remove the connector from the stud.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 10241
9. NOTE: LH shown, RH similar.
Lower the setting blocks. Use a flat screwdriver to release the setting block and lower.
10. NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting.
Using the special tool, cut the urethane adhesive from the windshield glass starting at the top
center and working toward the bottom corners.
11. Using the special tool, distance the windshield from the body.
12. NOTE:
- Removing the windshield glass requires more than one technician.
- Be sure not to scratch the pinch weld while removing windshield glass.
Using the special tool, cut the remaining urethane adhesive and remove the window glass.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 10242
13. Using a soft brush or vacuum, remove any dirt and foreign material from the pinch weld.
Installation
1. NOTE: Raise the setting block until flush with top. Lock the blocks into place after windshield is
installed.
Raise the setting blocks.
2. Dry fit the windshield. Make alignment marks with tape or non-staining pencil.
3. NOTE: Avoid scratching the pinch weld. For minor scratches or exposed metal on the pinch
weld, see manufacturer's recommendations.
Using an appropriate tool, trim the urethane adhesive leaving a 1-mm to 2-mm base of original
equipment urethane on the pinch weld.
4. CAUTION: Be sure to use the same brand and cure-rate products for the adhesive and primer.
Do not mix different brands of urethane
and primer. Refer to the Material Chart in this procedure.
NOTE: Sika uses the same black primer for the glass and pinch weld area.
Apply urethane glass primer according to manufacturer's instructions. Allow at least 6 minutes to
dry.
5. Cut the urethane applicator tip to specification.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Procedures
> Page 10243
6. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane
with less effort and continuous bead.
Apply urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld.
Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
7. NOTE: Inspect the flat foil connectors at the bottom of the new windshield for damage prior to
installation. Do not install a windshield with
damaged flat foil connectors.
Install the windshield by aligning it to the marks previously made.
8. CAUTION: When installing urethane-installed glass parts, the vehicle must not be driven until the
urethane has cured. Adequate cure
time is specified on the drive away chart for each urethane product as the temperatures and
humidity vary. Inadequate or incorrect curing can adversely affect the retention of the windshield.
After the urethane has cured, check the windshield glass seal for air or water leaks through the
urethane adhesive bead and add urethane adhesive as necessary.
9. NOTE: Follow the same routing for the electrical connector that was used during removal.
If equipped, connect the heated windshield electrical connectors.
10. Install the cowl panel grille. 11. Install the wiper pivot arms. 12. Raise the headliner and
position. 13. If equipped, install the roof opening panel trim. 14. Install the interior mirror. 15. Install
the sun visors, retainers and, if equipped, the overhead console. 16. Install the RH and LH side
A-pillar trim panels. 17. Clean the exterior and interior of the windshield glass with glass cleaner.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations > Page 10249
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations > Page 10254
C138
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Multifunction Switch
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations > Multifunction Switch > Page 10259
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Multifunction Switch
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 10262
C2347
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10265
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 10266
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 10267
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 10268
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 10272
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 10275
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Multifunction Switch, Wiper/Washer Portion > Page 10276
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Page 10277
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Page 10278
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations
> Page 10282
C138
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations
View 151-3 (Engine Compartment - 4.6L, 1 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations >
Page 10286
C137
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service
and Repair
Windshield Washer Pump: Service and Repair
WASHER PUMP
Removal and Installation
WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all
cautions and warnings indicated on the label of the container. Failure to follow these instructions
could result in personal injury.
CAUTION:
- When servicing the windshield washer pump be careful not to damage the windshield washer
pump seal.
- Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure
to do so could result in premature pump failure.
1. Disconnect the windshield washer reservoir hoses. 2. Disconnect the windshield washer pump
electrical connector. 3. Remove the windshield washer pump. 4. To install, reverse the removal
procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair
Windshield Washer Reservoir: Service and Repair
WASHER RESERVOIR
Removal and Installation
WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all
cautions and warnings indicated on the label of the container. Failure to follow these instructions
could result in personal injury.
CAUTION:
- When servicing the windshield washer pump, be careful not to damage the windshield washer
pump seal.
- Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure
to do so could result in premature pump failure.
1. Remove the air cleaner assembly. 2. Remove the RH front fender splash shield.
3. Disconnect the windshield washer pump electrical connector.
4. Disconnect the windshield washer solvent level electrical connector.
NOTE: If necessary, drain the windshield washer reservoir after removal.
5. Disconnect the windshield washer reservoir hoses.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair > Page 10293
6. Remove the top bolt.
- To install, tighten to 5 Nm (44 lb-in).
7. Remove the side bolt.
- To install, tighten to 5 Nm (44 lb-in).
8. Remove the bolt.
- To install, tighten to 5 Nm (44 lb-in).
9. Remove the windshield washer pump reservoir.
10. Transfer components as necessary. 11. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Multifunction Switch
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Multifunction Switch > Page 10298
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Multifunction Switch
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Multifunction Switch > Page 10301
C2347
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 10304
Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Multifunction Switch > Page 10305
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Page 10306
Windshield Washer Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Page 10307
3. Remove the 3 screws and the upper and lower steering column shroud. 4. Disconnect the
multi-function switch electrical connector. 5. Remove the 2 multi-function switch screws and the
multi-function switch. 6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments
Wiper Arm: Adjustments
WIPER BLADE AND PIVOT ARM ADJUSTMENT - WINDSHIELD
1. Cycle and park the windshield wipers.
2. Verify the distance between the center of the (1) RH windshield wiper blade and the (3) bottom
of the windshield glass to be sure the distance is
within specification.
3. Verify the distance between the center of the (2) LH windshield wiper blade and the (3) bottom of
the windshield glass to be sure the distance is
within specification.
4. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to
specification.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front
Wiper Arm: Service and Repair Wiper Pivot Arm - Front
WIPER PIVOT ARM - FRONT
1. Remove the wiper pivot arm.
1 Pull up on the pivot arm.
2 Pull out on the retaining tab and remove the pivot arm.
2. NOTE: The windshield wiper motor must be cycled to make sure that it is in the park position. If
necessary, adjust the wiper pivot arms.
To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 10313
Wiper Arm: Service and Repair Wiper Pivot Arm - Rear
WIPER PIVOT ARM - REAR
Removal
1. Remove the wiper pivot arm cover.
2. Remove the wiper pivot arm.
1 Remove the pivot arm nut.
2 Remove the wiper pivot arm.
Installation
1. NOTE: Before installation, be sure that the rear window wiper motor is in the park position.
Turn the wiper switch ON and OFF to allow the rear window wiper motor to cycle and stop in the
park position.
2. Position the wiper pivot arm.
3. Install the pivot arm nut.
- Tighten to 17 Nm (13 lb-ft).
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front > Page 10314
4. Install the wiper pivot arm cover. 5. Operate the rear window wiper for one cycle to be sure that
the pivot arm is in the correct position when the rear window wiper motor is in the
park position.
If the pivot arm is not in the correct position, remove the pivot arm and repeat Steps 1 through 4.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations
View 151-4 (Engine Compartment - 4.6L, 2 Of 2)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions
Wiper Motor: Diagram Information and Instructions
Introduction
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 diagrams 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 that 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. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set 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. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in Power and Distribution Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagrams in Power and Ground Distribution Diagrams. Splices connected to grounds can be seen
completely in Power and Ground Distribution Diagrams. For all other splices, a reference is given
to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in Vehicle/Diagrams.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10320
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System; and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in
Symbols.
Fuse and Relay Information
Fuse and Relay Information contains a view of the fuse/relay box in which fuses and relays are
identified, numbered and named. Fuse and relay numbering and naming follow the indication of the
fuse panel cover. In addition, for all removable relays, pin positions are added to illustrate proper
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10321
orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10322
Ground Distribution
Power and Ground Distribution Diagrams contains the diagrams that shows the complete details
for each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set of diagrams as uncluttered as possible.
C904
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and the connector number. The circuit function charts are
located each connector. The wiring harness designations are listed in set Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10323
Location information that can be found at the vehicle level will 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, along with a reference to the component location views.
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 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, tail pipe,catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery cell. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbols
Symbols Part 1
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10324
Symbols Part 2
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10325
Symbols Part 3
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10326
Symbols Part 4
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10327
Symbols Part 5
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10328
Wiper Motor: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The illustrations are known examples of wiring harness, splices and connectors that will create
intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical
evaluation 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.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminals by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10329
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Male half
7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10330
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground
2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10331
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10332
3. Install heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10333
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 1/4" (6.35mm) of insulation from each wire end, taking
care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10334
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, squeeze tool handles until ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10335
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10336
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 10337
C125
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield
Wiper Motor: Service and Repair Wiper Motor - Windshield
WIPER MOTOR - WINDSHIELD
Removal and Installation
1. Remove the front wiper pivot arms. 2. Remove the RH cowl grille panel. 3. Remove the LH cowl
grille panel.
4. Disconnect the windshield wiper motor electrical connector.
- Unclip the wiring harness from the wiper arm.
- Position the wiring harness aside.
5. Remove the 3 windshield wiper assembly mounting bolts.
- To install, tighten to 15 Nm (11 lb-ft).
6. Remove the windshield wiper assembly and position on a workbench.
7. Remove the windshield wiper motor mounting arm bolt and the wiper motor mounting arm.
- To install, tighten to 15 Nm (11 lb-ft).
8. Remove the 3 windshield wiper motor mounting bolts.
- To install, tighten to 15 Nm (11 lb-ft).
9. Remove the windshield wiper motor.
10. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 10340
Wiper Motor: Service and Repair Wiper Motor - Rear Window
WIPER MOTOR - REAR WINDOW
Removal and Installation
1. Remove the rear wiper pivot arm.
2. Remove the rear window wiper motor grommet.
1 Remove the pivot shaft nut. To install, tighten to 10 Nm (89 lb-in).
2 Remove the grommet.
3. Open the liftgate window.
4. Remove the wiper motor cover trim panel.
5. Remove the rear window wiper motor.
1 Disconnect the electrical connectors.
2 Remove the 2 rear window wiper motor nuts. To install, tighten to 6 Nm (53 lb-in).
3 Remove the rear window wiper motor.
6. To install, reverse the removal procedure.
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 10344
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
View 151-13 (Instrument Panel)
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
10348
C202
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch, Wiper/Washer Portion
Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch, Wiper/Washer Portion > Page 10351
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Multifunction Switch, Wiper/Washer Portion > Page 10352
Ford Explorer Sport Trac 4wd Workshop Manual (V8-4.6L VIN 8 (2007))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Page 10353
Wiper Switch: Service and Repair
Steering Column Multifunction Switch
Steering Column Multifunction Switch
Removal and Installation
CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or
damage to the column can result.
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
2 screws and the steering column opening cover.