Ford - Explorer Sport Trac 4wd - Workshop Manual - 2009 - 2009

Factory Workshop Manual Make Ford Model Explorer Sport Trac 4wd Engine and year V6-4.0L (2009) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8 Accessory Delay Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 22 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 23 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 28 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 29 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 39 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 40 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 45 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 46 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 49 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 52 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 53 Communications Control Module: Diagrams Audio Control Module (ACM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 54 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 55 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures Communications Control Module: Procedures Accessory Protocol Interface Module (APIM) Software Level Check Accessory Protocol Interface Module (APIM) Software Level Check NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM) Programming in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current APIM software level. - The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. The scan tool displays the following information: - Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM - Installed date: date the APIM was installed - Radio: currently identified ACM in the vehicle - HW Part No.: APIM hardware part number - Un-installed date: date (if any) the APIM was uninstalled - S/N: APIM serial number - Last Recorded State - Software Date/Time: date and time of last recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 58 - Description: a description of the content of the software revision - History - Software Date/Time: date and time of any recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time - Description: a description of the content of the software revision - Available Software for Programming Select: allows the software package to be selected - Lineage: the original software release, if the software available is a revision - VIP: VIP software level that is available with the selection - CIP: CIP software level that is available with the selection - Description: a description of the content of the software revision 9. Click a CIP software level to view the device compatibility list associated with the CIP software level, if desired. 10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port, or exit the OASIS screen. Audio Control Module (ACM) Self-Diagnostic Mode Audio Control Module (ACM) Self-Diagnostic Mode Audio Systems Without Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after Step 3 by turning the ACM off. Before the speaker walk test is complete, carry out any of the following actions: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 59 5. To exit the self-diagnostic mode, turn the ACM off. Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval - Vehicles Without Navigation 1. Operate the audio system in satellite radio mode. 2. Press and hold the AUX button and preset button 1, simultaneously. - The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN) displays on the screen. 3. Record the SDARS module ESN. 4. Turn the audio system off. Audio Systems With Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this step, or by allowing the speaker walk test to complete on its own. Before the speaker walk test is complete, press the "End Test" selection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 60 5. The following tests are available through the "BEZEL DIAGNOSTICS" menu: 6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL DIAGNOSTICS" menu. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 61 Communications Control Module: Removal and Replacement Audio Control Module (ACM) Audio Control Module (ACM) Removal and Installation NOTE: It is not necessary to remove the Audio Control Module (ACM) to retrieve the part number. For additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode See: Procedures/Audio Control Module (ACM) Self-Diagnostic Mode. 1. NOTE: Module configuration is required when a new ACM is being installed. Upload the ACM configuration information to the scan tool. 2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM. - Disconnect the ACM electrical connectors. 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Floor Console Components Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 62 Accessory Protocol Interface Module (APIM) Removal and Installation 1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software and hardware level when a new APIM is being installed to make sure that the new component is the same version as the component being replaced. Retrieve and record the current APIM software and hardware level. For additional information, refer to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory Protocol Interface Module (APIM) Software Level Check. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 63 2. Remove the 4 screws and the front floor console stowage door. 3. Remove the 2 screws and the front floor console rear trim panel. - Pull straight back to disengage the clips. 4. Remove the 2 screws and the front floor console finish panel. - Pull straight up to disengage the clips. 5. Remove the front floor console stowage bin. - Remove the 4 screws. - Disconnect the audio input jack electrical connector. - Disconnect the Universal Serial Bus (USB) port electrical connector. - Disconnect the APIM electrical connector. - Disconnect the USB cable electrical connector (at the APIM). 6. Remove the 4 screws and the APIM. 7. To install, reverse the removal procedure. - If a new APIM is being installed, program the APIM to the correct software level. Universal Serial Bus (USB) Cable and Port Universal Serial Bus (USB) Cable and Port Floor Console Components Universal Serial Bus (USB) Cable And Port-To-Bezel Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 64 USB Cable And Port-To-Accessory Protocol Interface Module (APIM) Removal and Installation 1. Remove the 4 screws and the front floor console stowage door. 2. Remove the 2 screws and the front floor console rear trim panel. - Pull straight back to disengage the clips. 3. Remove the 2 screws and the front floor console finish panel. - Pull straight up to disengage the clips. 4. Using a suitable tool (such as a trim removal tool) pry the audio input jack bezel from the storage bin. - Disconnect the audio input jack electrical connector. 5. Disconnect the Universal Serial Bus (USB) port connector from the audio input jack bezel. 6. Remove the 4 screws and the front floor console stowage bin. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 65 7. Remove the USB cable and port. - Disconnect the electrical connector. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 74 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 75 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 80 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 81 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 82 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 83 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 84 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 85 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 86 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 87 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 88 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 89 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 90 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 96 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 97 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 102 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 103 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 104 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 105 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 106 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 107 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 108 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 109 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 110 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 111 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 112 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 117 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 118 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 124 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 125 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 139 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 140 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 149 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 150 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 156 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 157 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 166 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 167 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 173 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 174 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 178 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 179 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 180 Parking Assist Control Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 181 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 182 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 183 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) - Explorer Sport Trac Removal and Installation 1. Remove the cab rear trim panel. 2. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker clips. - Remove the parking aid speaker. 3. If replacing the Parking Aid Module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM screw. - Remove the PAM. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 188 Memory Positioning Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 189 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 190 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 191 Memory Positioning Module: Service and Repair Driver Seat Module (DSM) Removal and Installation NOTICE: 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 Driver Seat Module (DSM) after installation. 1. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: When a new DSM is installed, it is necessary to download the module configuration information from the scan tool into the new DSM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 192 To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Power Seat Relay: Locations Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 197 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 198 Power Seat Relay: Locations Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 199 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 202 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 205 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 206 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 207 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 211 Auxiliary Step / Running Board Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 212 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 213 Auxiliary Step / Running Board Module: Service and Repair Power Running Board (PRB) Module Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the Power Running Board (PRB) module electrical connectors. 3. Remove the 3 screws and the PRB 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 (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion NOTE: Power seat track shown, manual seat track similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 217 NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 218 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 219 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 220 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 224 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 225 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 229 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 230 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 235 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 236 Electronic Brake Control Module: Diagrams Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 237 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 238 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation NOTICE: Electronic modules are sensitive to electrical charges. The Anti-lock Brake System (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 Programmable Module Installation in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control Unit (HCU) See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. 2. Remove the 4 screws and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 3. NOTICE: Make sure that the Anti-lock Brake System (ABS) module is properly seated to the Hydraulic Control Unit (HCU) and that the torque of the ABS module screws is correct, or damage to the components can occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 242 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 248 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 249 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Blower Motor Relay 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Blower Motor Relay 2 > Page 252 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 255 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 256 Blower Motor Relay: Testing and Inspection Blower Motor Relay 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 257 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 258 Blower Motor Relay: Testing and Inspection Blower Motor Relay 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 259 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 263 Compressor Clutch Relay: Description and Operation Engine Control Components Air Conditioning (A/C) Clutch Relay (A/CCR) Note: The PCM parameter identifiers (PIDs) wide open throttle air conditioning cutoff (WAC) and wide open throttle air conditioning cutoff fault (WAC_F) 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 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 (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 264 Compressor Clutch Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 265 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 269 Control Module HVAC: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 270 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 280 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 286 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 295 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 301 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 306 Fog/Driving Lamp Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 307 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 314 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 315 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 320 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 324 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 328 NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. 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. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. 9. 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. 10. NOTICE: 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 (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11. If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. 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 Remote Keyless Entry (RKE) transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower right SJB bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 329 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 (177 lb-in). 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. 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. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. NOTE: When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. Download the SJB configuration information from the scan tool into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming 15. 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. 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 333 Power Distribution Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 334 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 335 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) Relay Box: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 340 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 341 Relay Box: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 342 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 343 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 344 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 345 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 346 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 349 Relay Box: Diagrams Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 350 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 351 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 352 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 353 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 354 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 357 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 358 Relay Box: Application and ID Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 359 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. 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), which delivers 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 torque-based 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 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: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2 wires). - There are two designs: parallel and in-line. 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-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - 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. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP 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). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. For additional information on the APP sensor, refer to Engine Control Components See: Powertrain Management/Computers and Control Systems/Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy 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) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 365 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 two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring 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, appropriate corrective action is taken. ETC System With A 3-Track APP Sensor Failure Mode And Effects Management: a - ETC illuminates or displays a message on the message center immediately; MIL illuminates after 2 driving cycles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 366 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management: Electronic Throttle Monitor Operation: a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. APP and TP Sensor Inputs Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 367 Accelerator Pedal Position (APP) Sensor Check: Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Throttle Position (TP) Sensor Check: a - Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check: a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 376 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 377 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 383 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 384 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 385 Engine Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 386 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 387 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 388 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 389 Engine Control Module: Diagrams C175B Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 390 C175B Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 391 C175E Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 392 C175E Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 393 C175E Part 3 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 394 C175T Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 395 C175T Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Description The EEPROM is contained in an integrated circuit 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 DTC 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. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. 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. Neutral Profile Correction In order for the misfire detection system to function properly, any mechanical inaccuracies in the crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is reset. Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should also be relearned any time the CKP sensor is replaced or major engine repairs have been completed. To determine if the neutral profile learning has been completed, check the MP_LRN parameter identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any misfire DTCs. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer 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 be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old PCM 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 programmed PCM 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Procedures > Page 398 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 (V6-4.0L (2009)) 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 > Procedures > Page 399 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) A/C Tube Brackets PCM Removal All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Procedures > Page 400 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning Vehicles equipped with a 4.6L (3V) engine 2. Remove the Air Cleaner (ACL). All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the 2 bolts and the PCM. Installation All vehicles 1. Install the PCM and the 2 bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). 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 ACL. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft System (PATS) Parameter Reset Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 404 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 405 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations > Page 410 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Fuel Pump Driver Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Fuel Pump Driver Module > Page 416 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 417 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Control Unit > Component Information > Locations > Page 418 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) - Explorer Sport Trac Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector. 3. Remove the 2 bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 422 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 423 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 427 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 428 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 433 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 434 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 437 Air Bag Control Module: Diagrams Restraints Control Module (RCM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 438 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 439 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 440 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) Removal WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). Failure to follow these instructions may result in component damage and/or system failure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: When installing a new Restraints Control Module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. NOTE: The air bag warning indicator illuminates when the correct RCM fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. If installing a new RCM, carry out the steps necessary to prepare for Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 441 3. Remove the front floor console. 4. Disconnect the large 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 1. Install the RCM. 2. Install the 3 RCM nuts. - Tighten to 12 Nm (106 lb-in). 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. NOTICE: Putting the large electrical connector into the Restraints Control Module (RCM) on an angle may cause bad electrical connections and damage components. Position the large electrical connector into the RCM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 442 6. Connect the large RCM connector. - NOTICE: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the Restraints Control Module (RCM), before using the lever to fully seat the connector. Damage to the connector or component may occur. With the large 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 front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 9. When installing a new RCM, carry out the steps necessary to complete Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 10. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 446 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 447 Seat Occupant Classification Module - Air Bag: Service and Repair Occupant Classification System Module (OCSM) NOTE: Power seat shown, manual seat similar. Removal NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Disconnect the Occupant Classification System Module (OCSM) electrical connector underneath the front of the passenger seat. 3. NOTE: Note the position of the locator tab on the OCSM for installation. Remove the 2 screws and the OCSM. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 6. Carry out the appropriate procedure after installation of an Occupant Classification Sensor (OCS) system component. - If installing the original OCS system component, carry out the OCS System Zero Seat Weight Test and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics. - If installing a new OCS system component, carry out the OCS Reset and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Restraint Systems/Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 453 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay Starter Relay: Testing and Inspection Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 456 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 457 Starter Relay: Testing and Inspection Run/Start Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 458 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 469 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 470 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 476 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 477 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 482 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 485 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 486 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 487 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 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 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 492 Heated Glass Element Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 493 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 498 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 502 Wiper Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 503 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 510 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 511 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 512 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 513 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 514 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 515 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 516 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 519 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 520 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 521 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 522 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Mountaineer, Explorer Sport Trac NOTE: Mountaineer shown, Explorer Sport Trac similar. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 526 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 530 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 535 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 540 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 543 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 544 Power Door Lock Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 545 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 546 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. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 550 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 551 Power Mirror Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 552 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 553 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 554 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch Removal and Installation 1. Remove the front door trim panel. 2. Depress the 2 retaining tabs and 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left Power Seat Switch: Locations Third Row Folding Seat Switch, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 559 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 560 Power Seat Switch: Locations Third Row Folding Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 561 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 562 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 563 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 566 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 567 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 568 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 569 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 572 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 573 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 574 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 575 Power Seat Switch: Testing and Inspection Power Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 576 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front Power Seat Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 579 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 580 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 581 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 582 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 583 Power Seat Switch: Service and Repair Memory Set Switch 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 584 Power Seat Switch: Service and Repair Seat Control Switch Seat Control Switch Removal and Installation All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Body and Frame/Seats/Service and Repair/Front Seats/Seat - Front. 2. Remove the cushion side shield in the following sequence. 1. Remove the clip and manual recline handle (if equipped). 2. Pull and remove the manual lumbar control knob (if equipped). 3. Remove the scrivet. 4. Remove the retention bracket screw and the retention bracket (if equipped). 5. Release the cushion side shield front clip. 6. From under the cushion side shield, release the 3 hook retainers. 7. Pull out on the cushion side shield at the back and release the pin-type retainer. 8. Separate the cushion trim cover elastic strap from the cushion side shield. 9. 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. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Body and Frame/Seats/Service and Repair/Front Seats/Seat - Front. Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 585 Power Seat Switch: Service and Repair Seat Control Switch - Third Row Seat Control Switch - Third Row Removal and Installation NOTE: The third row seat control switches are located in the LH quarter trim panel. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations Power Sliding Door Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 589 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 590 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 591 Power Sliding Door Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 592 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 596 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 597 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Window Latch Actuator Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 601 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 604 Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 605 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 606 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 607 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 608 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 612 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 619 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 624 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair Acceleration/Deceleration Sensor: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. - To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 628 - To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 632 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 633 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 637 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 638 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 642 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 643 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 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 screws and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 650 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 651 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 lb-in). 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 center finish panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 656 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 657 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 658 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 659 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 660 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 661 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 662 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 665 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 666 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 667 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 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. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt and the wheel speed sensor. - To install, tighten the bolt to 17 Nm (150 lb-in). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 670 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 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 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 671 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear Wheel Speed Sensor Ring - Rear Removal 1. Remove the rear halfshaft. 2. Using a suitable driver, remove the ABS wheel speed sensor ring. Installation 1. Install the new ABS wheel speed sensor and the Wheel Speed Sensor Ring Installers on the halfshaft as shown. 2. Using the Wheel Speed Sensor Ring Installers, install the ABS wheel speed sensor ring as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 672 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Fan Speed Sensor (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 PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. For additional information on the cooling fan clutch, refer to the Cooling Fan Clutch. Cooling Fan Clutch with Fan Speed Sensor (FSS) Cooling Fan Clutch with FSS Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 681 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 682 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Control Components Engine Coolant Temperature (ECT) Sensor The ECT 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 ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Typical Thread Type Sensor Typical Thread Type ECT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 683 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC Removal and Installation 1. Drain the cooling system. 2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 687 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 688 Engine Temperature Sensor: Description and Operation Engine Control Components Cylinder Head Temperature (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. For additional information, refer to Powertrain Control Software See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 693 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 694 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 697 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch Engine Control Components 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 (V6-4.0L (2009)) 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 Engine Control Components 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. Typical Clutch Pedal Position (CPP) Switch Typical Clutch Pedal Position (CPP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Explorer shown, Mountaineer similar. Removal and Installation NOTE: It is not necessary to remove the driver air bag module during this procedure. NOTE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 708 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 709 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Control Components Engine Oil Temperature (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. Typical Thread Type Sensor Typical EOT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 717 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 718 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 719 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Climate Control System Component Tests Temperature Sensor - Ambient Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 723 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 724 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 728 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 729 Cabin Temperature Sensor / Switch: Testing and Inspection Climate Control System Component Tests Temperature Sensor - In-Vehicle Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor > Page 732 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor 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 (V6-4.0L (2009)) 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 Engine Control Components Air Conditioning Evaporator Temperature (ACET) Sensor 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 and improve defrost/demist performance. Note: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 739 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 742 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch Engine Control Components Air Conditioning (A/C) Cycling Switch The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to the Climate Control System Air Conditioning System Overview. Also, refer to the applicable Wiring Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to wide open throttle air conditioning cutoff (WAC). Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 745 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch Engine Control Components Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled for electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. For additional information, refer to the Climate Control System, Air Conditioning System Overview or the Wiring Diagrams. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 746 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP) Transducer Sensor Engine Control Components Air Conditioning Pressure (ACP) Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. A/C Pressure Transducer Sensor Output Voltage Vs Pressure Chart Typical ACP Transducer Sensor Typical ACP Transducer Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 750 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 759 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 760 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 761 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 762 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 765 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 766 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 767 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 768 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door Door Ajar Switch - Front Door Removal and Installation 1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 771 Door Switch: Service and Repair Door Ajar Switch - Liftgate Door Ajar Switch - Liftgate Removal and Installation 1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 772 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass Door Ajar Switch - Liftgate Glass Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 773 Door Switch: Service and Repair Door Ajar Switch - Rear Door Door Ajar Switch - Rear Door Removal and Installation 1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Engine Control Components 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. Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 779 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir Engine Control Components 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 ignition 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 780 Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 781 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 782 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 783 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 787 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 788 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 793 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 794 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 798 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 799 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 803 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 804 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 805 Brake Light Switch: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 806 Brake Light Switch: Service and Repair Stoplamp Switch Removal and Installation NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 811 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 812 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 813 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 814 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 817 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 818 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 819 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 820 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door Door Ajar Switch - Front Door Removal and Installation 1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 823 Door Switch: Service and Repair Door Ajar Switch - Liftgate Door Ajar Switch - Liftgate Removal and Installation 1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 824 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass Door Ajar Switch - Liftgate Glass Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 825 Door Switch: Service and Repair Door Ajar Switch - Rear Door Door Ajar Switch - Rear Door Removal and Installation 1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 830 Headlamp Dimmer Switch: Locations Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 831 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 834 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 837 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 838 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 839 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 840 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 844 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 845 Headlamp Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 846 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 847 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 854 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 855 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 856 Turn Signal Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 857 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 858 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 864 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 865 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 869 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 870 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 871 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 872 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 873 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 878 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 879 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 882 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 883 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 884 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 885 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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. Typical Clutch Pedal Position (CPP) Switch Typical Clutch Pedal Position (CPP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 892 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 893 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Control Components Engine Coolant Temperature (ECT) Sensor The ECT 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 ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Typical Thread Type Sensor Typical Thread Type ECT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 894 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC Removal and Installation 1. Drain the cooling system. 2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 898 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 899 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 900 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 901 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 902 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 906 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 907 Engine Temperature Sensor: Description and Operation Engine Control Components Cylinder Head Temperature (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. For additional information, refer to Powertrain Control Software See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 913 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 914 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 915 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 916 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Fuel Pump (FP). For additional information, refer to Fuel Pump See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 917 Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the FP body. 2. Route the fuel level sender wire through the center of the FP. 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the FP and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 918 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the FP. For additional information, refer to Fuel Pump See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 922 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 923 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 924 Fuel Tank Pressure Sensor: Description and Operation Engine Control Components Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 925 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Removal and Installation WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Evaporative Emission (EVAP) canister. For additional information, refer to Evaporative Emission Canister See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Evaporative Emission Control Canister/Service and Repair. 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel Pump (FP) module and the vapor vent valves. 5. Remove the FTP sensor and vapor tube assembly. 6. To install, reverse the removal procedure. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Intake Air Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 929 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 930 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 931 Intake Air Temperature Sensor: Description and Operation Engine Control Components Intake Air Temperature (IAT) 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 sensor 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. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two 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 two IAT sensors. Both sensors are thermistor type devices and operate as described above. 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. Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors 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 Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type MAF sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 935 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 936 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 937 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 938 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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. Typical Manifold Absolute Pressure (MAP) Sensor Typical Manifold Absolute Pressure (MAP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Control Components Engine Oil Temperature (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. Typical Thread Type Sensor Typical EOT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 949 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 950 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 951 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 952 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 953 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 954 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 955 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 956 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 957 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 960 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 961 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 962 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Engine Control Components 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. Typical Heated Oxygen Sensor (HO2S) Typical Heated Oxygen Sensor (HO2S) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) > Page 965 Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S) Engine Control Components Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View > Page 968 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the HO2S electrical connector. 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. Installation 1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the HO2S electrical connector. 4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View > Page 969 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the CMS electrical connector. 4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. Installation 1. Apply a light coat of anti-seize lubricant to the threads of the CMS. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the CMS electrical connector. 4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 973 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 EPC pressure during increased engine load, for example during parking maneuvers. Typical Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 976 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Engine Control Components 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 EPC pressure during increased engine load, for example, during parking maneuvers. Typical Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) 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 > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 982 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 986 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 987 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor > Page 990 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 991 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 992 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 993 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 997 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 998 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 999 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1000 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1001 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1002 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1003 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1004 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1005 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) 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 1010 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) Engine Control Components 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 speed, 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. Typical Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 1017 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1022 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1023 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1027 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1028 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1029 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1030 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1031 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) 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 Pressure Sensor/Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1035 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1036 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1037 Fuel Pressure Sensor/Switch: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1038 Fuel Pressure Sensor/Switch: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 1039 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1043 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1044 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1045 Fuel Temperature Sensor: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1046 Fuel Temperature Sensor: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 1047 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1051 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1052 Inertia Fuel Shutoff Switch: Description and Operation Engine Control Components Inertia Fuel Shut-off (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone 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, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1053 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. NOTE: 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 2 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 (V6-4.0L (2009)) 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 Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1057 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1058 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Powertrain Management/Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor > Page 1061 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1062 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1063 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1064 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1070 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1071 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1074 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1075 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1076 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 1077 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1081 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1082 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1083 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1084 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1085 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Lock Cylinder - Functional 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. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys must be programmed. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1091 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Lock Cylinder - Non Functional Removal 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. 3. Program the new PATS keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1095 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1096 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1097 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1098 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor Impact Sensor: Locations RH Front Impact Severity Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1104 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1105 Impact Sensor: Locations LH Front Impact Severity Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1106 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1107 Impact Sensor: Locations Side Impact Sensor, Second Row Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1108 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1109 Impact Sensor: Locations Side Impact Sensor, Second Row Passenger Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1110 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1111 Impact Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1112 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1113 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1114 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1115 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1116 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1117 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1118 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1119 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 1120 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1123 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1124 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1125 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1126 Impact Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1127 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 1128 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the 4 pin-type retainers and lower radiator air deflector. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the bolt and front impact severity sensor. To install, tighten to 12 Nm (106 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1131 5. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1132 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar Side Impact Sensor - C-Pillar, Explorer Sport Trac NOTE: RH shown, LH similar. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: The RH and LH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1133 - 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. NOTE: Note the position of the sensor and bracket locating tab for installation. NOTE: 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 (106 lb-in). 7. Disconnect the electrical connector and remove the side impact sensor. 8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 9. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 1134 Impact Sensor: Service and Repair Side Impact Sensor - Front Door Side Impact Sensor - Front Door NOTE: LH side shown, RH similar. Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the weathershield on the door to access the side impact sensor (pressure sensor). 4. Disconnect the electrical connector. 5. Remove the bolt and side impact sensor. - To install, tighten to 9 Nm (80 lb-in). 6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 7. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 1139 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 1142 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > OCS Rail 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > OCS Rail 1 > Page 1147 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1148 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor NOTE: Outboard Occupant Classification Sensor (OCS) rail shown, inboard similar. Removal WARNING: The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat or dropped after it is installed to a front passenger seat track assembly. Use care when handling an OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. WARNING: Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat track may be removed and installed. Failure to follow these instructions may result in incorrect operation of the OCS system and increase the risk of serious personal injury or death in a crash. WARNING: Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. WARNING: Use care when handling the front passenger seat and track assembly. Dropping the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle may result in damaged seat components. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1149 crash. NOTICE: Prevent oil and/or grease from getting on the Occupant Classification Sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the front passenger seat. 2. NOTICE: Before releasing the Occupant Classification Sensor (OCS) rail electrical connector, push only on the tip of the connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail electrical connector or damage to the electrical connector may occur. NOTE: Note the Occupant Classification Sensor (OCS) rail position, electrical wiring routing, wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers and 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 stop position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the OCS rail. 6. Move the seat to the rearward stop position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1150 7. NOTE: Note the locator tab position where the OCS rail goes through the rail shield and into the rear seat track mounting point for installation. Remove the 2 front bolts and OCS rail and shield. Installation NOTE: If installing a new seat track, position the seat track where the seat will be in the full rearward position before installing the OCS rails. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. 1. WARNING: To prevent foreign material and contaminants from entering the occupant classification sensor (OCS) rail, make sure the OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: Prevent oil and/or grease from getting on the Occupant Classification Sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Install the shield on the OCS rail, and install the OCS rail and shield on the seat track with the locator tab aligned correctly as shown. 2. Hold the OCS rail and shield firmly in position and install the front mounting position rear bolt. - Tighten to 25 Nm (18 lb-ft). 3. Hold the OCS rail and shield firmly in position and install the front mounting position front bolt. - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward stop position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 1151 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, route the wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion frame. - 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. 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. For additional information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics. - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Restraint Systems/Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Power seat shown, manual seat similar. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 3. Disconnect the seat position sensor electrical connector. 4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1158 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Lock Cylinder - Functional 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. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys must be programmed. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 1165 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Lock Cylinder - Non Functional Removal 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. 3. Program the new PATS keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1169 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 1170 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 1176 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 EPC pressure during increased engine load, for example during parking maneuvers. Typical Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1179 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Engine Control Components 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 EPC pressure during increased engine load, for example, during parking maneuvers. Typical Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1183 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 1184 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1189 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 1190 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training 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). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Programming and Relearning. 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. 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training > Page 1196 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. 8. 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. 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. 10. 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. 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 (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training > Page 1197 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. For additional information, refer to Wheel and Tire See: Maintenance/Wheels and Tires/Service and Repair/Overhaul. 2. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. 3. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1200 4. Remove the sensor. Assembly 1. NOTICE: Damage to the sensor may 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. 3. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire See: Maintenance/Wheels and Tires/Service and Repair/Overhaul. 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 See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1201 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor See: Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1202 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory-installed strap in the following 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 in) from the buckle. 2. Using a large screwdriver and a twisting motion, unbuckle the strap. 3. Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. - Discard the strap. 4. 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. NOTICE: Metal scrapers may 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. Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed. 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 degrees from the valve stem. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1203 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. NOTICE: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. 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 in) away from the sensor and tighten the worm gear. - Tighten to 3 Nm (27 lb-in). 6. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire. See: Maintenance/Wheels and Tires/Service and Repair/Overhaul 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. See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Mode Switch: Description and Operation Engine Control Components 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. Typical Transmission Control Switch (TCS) (Column Shift) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) (Floor Shift) Typical Transmission Control Switch (TCS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS) External Controls Transmission Control Switch (TCS) The Transmission Control Switch (TCS) is a momentary contact switch located on the selector lever knob. Pushing the TCS will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on the Instrument Cluster (IC). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) > Page 1214 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. 2. Remove the Transmission Control Switch (TCS) from the knob. Installation 1. Install the TCS into the selector lever knob. 2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1218 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1219 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1220 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1221 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1222 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1223 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1224 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1225 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1226 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1231 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1232 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 1233 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 1236 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 1237 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor 5R55S Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1240 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Turbine Shaft Speed (TSS) sensor connector. 8. Remove the TSS sensor. 1. Remove the TSS sensor screw. 2. Remove the TSS sensor from the transmission. - Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1241 Installation All vehicles 1. Inspect the TSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the TSS sensor into the transmission. 2. Tighten the TSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the TSS sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever bracket and selector lever bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1242 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1243 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor 5R55S Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1244 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Heated Oxygen Sensor (HO2S) connector from the transmission case. 8. Disconnect the Output Shaft Speed (OSS) sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1245 9. Remove the OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the OSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the OSS sensor into the transmission. 2. Tighten the OSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the OSS sensor connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1246 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1247 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1248 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor 5R55S Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1249 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor connector. 8. Remove the intermediate shaft speed sensor. 1. Remove the intermediate shaft speed sensor screw. 2. Remove the intermediate shaft speed sensor from the transmission. - Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1250 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the intermediate shaft speed sensor into the transmission. 2. Tighten the intermediate shaft speed sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the intermediate shaft speed sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 1251 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1256 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1257 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 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. 6. Disconnect the electrical connector(s). 7. Disengage the locking tangs and remove the Mode Select Switch (MSS) from the instrument panel center finish panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1258 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1264 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1265 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 1266 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1269 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1270 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1271 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 1272 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1275 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1276 Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and Rear Doors Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1277 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1278 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 (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1283 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1284 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1288 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1289 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Windshield Washer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1292 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1293 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1294 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1295 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1299 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1300 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch Wiper Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1303 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1304 Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 1305 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1306 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1312 Alignment: Specifications Ball Joint Deflection, Ride Height, Thrust Angle, and Vehicle Lean Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 1313 Alignment: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber 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 flagnut with a non-flagnut 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1316 Alignment: Description and Operation Caster 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 flagnut with a non-flagnut 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1317 Alignment: Description and Operation Drift/Pull 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 flagnut with a non-flagnut 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1318 Alignment: Description and Operation Nibble 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 flagnut with a non-flagnut 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1319 Alignment: Description and Operation Camber 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 flagnut with a non-flagnut 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 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 flagnut with a non-flagnut 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. 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. Drift/Pull 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 flagnut with a non-flagnut 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1320 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. Nibble 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 flagnut with a non-flagnut 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. 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 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 flagnut with a non-flagnut 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. 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. Shimmy 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 flagnut with a non-flagnut 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. 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. Toe 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 flagnut with a non-flagnut 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. Toe Positive Toe (Toe In) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page 1321 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. Incorrect Thrust Angle (Dogtracking) Wander 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 flagnut with a non-flagnut 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 following 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 lb-ft). 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 arm rearward nut. 6. Position the LF lower 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 arm rearward nut to 200 Nm (148 lb-ft). 8. Recheck the camber and caster, adjust as necessary. 9. Check and, if necessary, adjust the front toe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1324 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and adjust the gauge arm until the scriber point is located in the center of the lower arm inboard bolt. Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 2). 3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge arm until the scriber point is located in the center of the shock absorber lower bolt. Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 3). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1325 5. Subtract measurement 3 from measurement 2 to obtain the front ride height. - Refer to Specifications. Rear Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Measure the distance between the flat level surface and the center of the lower arm inboard bolt (measurement 2). 2. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (measurement 3). 3. Subtract measurement 3 from measurement 2 to obtain the rear ride height. - Refer to Specifications. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1326 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. 6. Rotate the front wheel inner tie rods until the toe setting is within specification. 7. NOTICE: 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 lb-ft). 8. Install the clamps. 9. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1327 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 lb-ft). 7. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 1328 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 flagnut must be removed and replaced with a non-flagnut 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. 3. Using alignment equipment and the manufacturer's instructions, measure the rear camber. 4. 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 in) 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. 5. NOTE: Make sure that the camber settings are not disturbed while tightening the nut. Tighten the upper arm inboard nut to 250 Nm (185 lb-ft). 6. Recheck the camber settings and adjust as necessary. 7. Check and, if necessary, adjust the rear toe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... ............................................207-276 kPa (30-40 psi) Engine running.................................................. .................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1333 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to Spring Lock Couplings See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Spring Lock Couplings. 4. NOTE: 4.6L shown, 4.0L similar. Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail. 5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 6. Connect the battery ground cable. 7. 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. 8. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 9. NOTE: 4.6L shown, 4.0L similar. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1334 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values Hot Idle ............................................................................................................ .......................................................................................... 750 - 820 RPM Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View Air Filter Element: Service and Repair Intake Air System Components - Exploded View Intake Air System Components - Exploded View Coolant Expansion Tank Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 1343 Intake Air System Components - 4.6L (3V) 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 1344 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element 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 (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL element. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious 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. NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Base ignition timing................................................................................................................10 degrees Before Top Dead Center (BTDC), Non-adjustable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Spark Plug Wires Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Powertrain Management/Ignition System/Description and Operation in the Description and Operation. Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ...............................................................Specification Spark Plug Gap.................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1362 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................17 Nm (150 lb-in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1363 Spark Plug: Application and ID Item....................................................................................................................................................... ...............................................................Specification Spark Plug type.................................................................................................................................... ....................................................................AGSF24N Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1364 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. - Install a new 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. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1365 6. Inspect for overheating, identified by white or light gray spots and a 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. - Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 1368 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Powertrain Management/Ignition System/Description and Operation in the Description and Operation. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs. Remove the spark plugs. - To install, tighten to 17 Nm (150 lb-in). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1372 Compression Check: Testing and Inspection Engine 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 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1373 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 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 within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Accessory Drive Belt Routing Front End Accessory Drive (FEAD) - 4.0L SOHC Front End Accessory Drive (FEAD) - 4.6L (3V) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Noise/Flutter Drive Belt: Testing and Inspection Drive Belt - Noise/Flutter Accessory Drive Drive Belt - Noise/Flutter NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. 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. 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 (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic transmissions. - WOT 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. - the A/C anti-slugging strategy executes after a long hot heat soak. - 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 or idler pulley(s) 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Noise/Flutter > Page 1379 Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation Accessory Drive Drive Belt - Incorrect Installation NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may 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 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 and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1382 Drive Belt: Service and Repair Accessory Drive Belt Accessory Drive Belt - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. To install, reverse the removal procedure. - For correct belt routing, refer to Accessory Drive See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Description and Operation, Accessory Drive Belt Routing, Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View Air Filter Element: Service and Repair Intake Air System Components - Exploded View Intake Air System Components - Exploded View Coolant Expansion Tank Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 1389 Intake Air System Components - 4.6L (3V) 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 1390 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element 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 (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL element. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious 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. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Powertrain Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S Fluid Filter - A/T: Service and Repair 5R55S Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission fluid pan. 3. Remove the transmission fluid pan drain plug and drain the transmission fluid. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 1401 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Installation 1. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid filter. - Tighten to 10 Nm (89 lb-in). 2. Install the transmission fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan gasket on the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 1402 4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws in a crisscross sequence. - Tighten to 11 Nm (97 lb-in). 6. Install the transmission fluid pan drain plug. - Tighten to 26 Nm (19 lb-ft). 7. Partially fill the transmission. For additional information, refer to Transmission Fluid Exchange See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/5R55S/Transmission Fluid Exchange or Transmission Fluid Drain and Refill See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/5R55S/Transmission Fluid Drain and Refill. Transmission Filter - In Line Transmission Filter - In Line Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 1403 NOTE: Use the following guidelines for installing the transmission fluid in-line filter: - If the transmission was overhauled and the vehicle was equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter. - If the transmission was overhauled and the vehicle was not equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter kit. - If the transmission is being installed for a non-internal repair, do not install an in-line transmission fluid filter or in-line transmission fluid filter kit. - If installing a Ford-authorized remanufactured transmission, install a new in-line transmission fluid filter. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the transmission fluid cooler connector. 3. Using the Transmission Disconnect Tool, disconnect the transmission fluid cooler connector. 4. Remove the section of the transmission fluid cooler tube at the second flare. - Clean and de-burr the cut end of the transmission fluid cooler tube. 5. NOTE: Be sure the transmission fluid cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the transmission fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional one and one-half turns to seat the ferrule in the connector. 6. Remove the section of the transmission fluid cooler hose as illustrated. 7. NOTICE: The transmission fluid cooler filter has a bypass valve in it. The red arrow on the transmission fluid filter indicates the direction of transmission fluid flow through the filter. The transmission fluid filter must be installed in the transmission fluid cooler return tube with the red arrow on the transmission fluid filter pointing away from the transmission fluid cooler and toward the transmission (the transmission fluid return tube has transmission fluid coming out of the transmission fluid cooler going to the transmission). If the transmission fluid filter is not installed correctly, it will cause internal transmission damage. NOTICE: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with a bend entering the transmission fluid Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 1404 filter greater than 60 degrees. Doing so can block transmission fluid flow and cause internal transmission damage. Install the one end of the transmission fluid filter into the transmission fluid cooler hose with a clamp. - Tighten the transmission fluid cooler hose clamp. 8. Using a suitable length of hose, install the other end of the transmission fluid filter into the tubing ferrule hose assembly with 2 clamps. - Tighten the hose clamps. 9. Clean a section of the transmission fluid pan, then install the sticker. 10. Fill the transmission with transmission fluid. - Verify for correct operation. - Check the filter for leaks. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 1405 Fluid Filter - A/T: Service and Repair 6R80 Fluid Pan, Gasket and Filter Removal NOTICE: The use of any transmission fluid other 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. 2. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. Remove the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 1406 Installation NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission fluid filter and seal assembly. The transmission 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 automatic transmission fluid. 3. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated. Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if required. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 1407 6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. - Tighten to 12 Nm (106 lb-in). 7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid. For additional information, refer to Transmission Fluid Drain and Refill See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious 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. NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair Coolant Line/Hose: Service and Repair Coolant Crossover Manifold Assembly Accessory Drive Belt Generator Coolant Crossover Manifold Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1416 Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Procedures/Cooling System Draining, Filling and Bleeding. 2. Remove the intake manifold. 3. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator pulley. 4. Disconnect the electrical connector. 5. Loosen the generator nuts. - To install, tighten to 25 Nm (18 lb-ft). 6. 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 lb-in). 7. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 8. Disconnect the heater hose from the coolant crossover manifold assembly. 9. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 10. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets. - To install, tighten to 10 Nm (89 lb-in). 11. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Page 1417 - Install new gaskets. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 - 4.0L SOHC Removal and Installation 1. Recover the refrigerant. 2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 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 compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1422 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1423 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line Condenser to Evaporator Line Removal and Installation All vehicles 1. Remove the Air Cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1424 - Discard the O-ring seal. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1425 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front Auxiliary Evaporator Outlet and Inlet Line - Front Removal and Installation 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1426 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1427 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear Auxiliary Evaporator Outlet and Inlet Line - Rear Removal and Installation 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1428 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1429 Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line - 4.0L SOHC Removal and Installation 1. Recover the refrigerant. 2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 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 compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1430 - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Condenser To Evaporator Line Condenser to Evaporator Line Removal and Installation All vehicles 1. Remove the Air Cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the 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). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1431 All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. 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. Auxiliary Evaporator Outlet and Inlet Line - Front Auxiliary Evaporator Outlet and Inlet Line - Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1432 Removal and Installation 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). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1433 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. Auxiliary Evaporator Outlet and Inlet Line - Rear Auxiliary Evaporator Outlet and Inlet Line - Rear Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1434 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. Suction Accumulator To Compressor Line Suction Accumulator to Compressor Line - 4.0L SOHC Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1435 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the compressor suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Release the brake booster vacuum hose clamp and disconnect the hose. 5. Remove the suction accumulator-to-compressor line bracket bolt at the dash panel. - To install, tighten to 11 Nm (97 lb-in). 6. Remove the suction accumulator outlet fitting nut. - To install, tighten to 8 Nm (71 lb-in). 7. Disconnect the auxiliary evaporator outlet line fitting (if equipped). - Discard the O-ring seals. 8. Remove the suction accumulator-to-compressor line. - Discard the O-ring seal. 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. Suction Accumulator To Evaporator Line Suction Accumulator To Evaporator Line Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1436 Removal and Installation All vehicles 1. Remove the suction accumulator. For additional information, refer to Suction Accumulator See: Heating and Air Conditioning/Accumulator HVAC/Service and Repair. 2. 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). 3. Remove the ground strap bolt at the dash panel. 4. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. Vehicles with 4.0L engine 5. Disconnect the Evaporative Emission (EVAP) return line fitting at the intake manifold. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1437 6. Remove the fuel line bracket bolt at the rear of the RH valve cover. 7. Remove the wire harness bolt at the rear of the RH cylinder head. All vehicles 8. Remove the suction accumulator-to-evaporator line. 9. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Auxiliary Heater Outlet and Inlet Line - Front Auxiliary Heater Outlet and Inlet Line - Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1438 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. Auxiliary Heater Outlet and Inlet Line - Rear Auxiliary Heater Outlet and Inlet Line - Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1439 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. - 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 1440 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: 4.6L engine shown, 4.0L engine similar. Removal NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Page 1444 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0L See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley or Power Steering Pump Pulley - 4.6L See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley. 3. Remove the steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the power steering fluid cooler 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). 7. Remove the pressure line bracket-to-crossmember bolt. 8. Disconnect the pressure line-to-pump fitting. - Remove and discard the Teflon(R) seal. 9. Remove the pressure line. Installation 1. NOTE: A new Teflon(R) seal must be installed. Using the Teflon(R) Seal Installer Set, install a new Teflon(R) seal on the pressure line fitting. 2. Position the pressure line and connect the pressure line-to-pump fitting. - Tighten to 65 Nm (48 lb-ft). 3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). - Tighten to 11 Nm (97 lb-in). 4. NOTE: New O-rings must be installed whenever the pressure line and fluid cooler are disconnected from the steering gear. 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 (106 lb-in). 6. Install a new O-ring seal and position the power steering fluid cooler 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 lb-ft). 8. Install the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0L See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley or Power Steering Pump Pulley - 4.6L See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley. 9. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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-C Ford Specification ................................................................................................................................................... WSS-M6C62-A or WSS-M6C65-A1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. .............................................. 12.2 quarts (11.5 liters) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1453 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY 5R55S .................................................................................................................................................. ............................................. 12.4 quarts (11.7 liters) 6R80 ................................................................ .................................................................................................................................. 11.2 quarts (10.6 liters) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1458 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION FLUID 5R55S .................................................................................... ........................................................................................... [1] Motorcraft MERCON V ATF Ford Part Number ................................................................................................................................................ .................................................. XT-5-QM Ford Specification ............................................................. ................................................................................................................................ MERCON V 6R80 .................................................................................................................................................... ........................... [2] Motorcraft MERCON LV ATF Ford Part Number ............................................... ................................................................................................................................................ XT-10-QLV Ford Specification ............................................................................................................. .............................................................................. MERCON LV Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S Fluid - A/T: Service and Repair 5R55S Transmission Fluid Level Check Transmission Fluid Level Check Transmission Fluid Fill Reference NOTE: Left side of case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1461 1. Using the scan tool, monitor the Transmission Fluid Temperature (TFT). 2. Start the engine. 3. NOTE: Engine idle speed is approximately 650 rpm. Run the engine until the TFT is between 27-49°C (80-120°F). 4. Move the selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the selector lever in the PARK position. 6. With the engine running and the vehicle set as close to level as possible, position it on a hoist. 7. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. 8. Install the Fluid Level and Fill Plug Adapter into the pan. 9. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure that the canister is clean. Fill the Fluid Transporter/Evacuator/Injector with transmission fluid. 10. Hang the Fluid Transporter/Evacuator/Injector under the vehicle. Position it upright and close to the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1462 11. Connect the Fluid Transporter/Evacuator/Injector. - Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the Rubber Tip Air Nozzle. Transmission fluid will immediately start flowing out of the Fluid Transporter/Evacuator/Injector into the transmission fluid pan. 13. Add 0.5L (1 pt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the Rubber Tip Air Nozzle from the end of the hose. 14. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. If the transmission fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 12 and 13. 15. Once the transmission is full, place a Vacuum Pump Kit on the open end of the vacuum/pressure hose on the Fluid Transporter/Evacuator/Injector and apply vacuum to the system. This will pull out any extra transmission fluid trapped in the system and direct it into the container. 16. Allow the transmission fluid to drain. Make sure that the TFT is between 27-49°C (80-120°F). When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. 17. Reinstall the small (center) transmission fluid level indicating plug. - Tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1463 18. Check the operation of the transmission by moving the selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Transmission Fluid Exchange Transmission Fluid Exchange NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products can cause internal transmission components to fail, which will affect the operation of the transmission. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid. 3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission fluid cooler tube after the transmission fluid cooler on the return tube. This will help remove any foreign material trapped in the transmission fluid coolers. 4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Follow the manufacturer's instructions included with the machine. 5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Reconnect any disconnected transmission fluid cooler tubes. 6. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1464 Fluid Fill Reference NOTE: Left side of case shown. Draining Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1465 1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. 2. Remove the transmission fluid drain plug (large plug) and allow the transmission fluid to drain. Refill 1. Install the transmission fluid drain plug. - Tighten to 26 Nm (19 lb-ft). 2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. 3. Install the Fluid Level and Fill Plug Adapter into the transmission fluid pan. 4. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure that the canister is clean. Fill the Fluid Transporter/Evacuator/Injector with transmission fluid. 5. Hang the Fluid Transporter/Evacuator/Injector under the vehicle, upright and close to the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1466 6. Connect the Fluid Transporter/Evacuator/Injector. - Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the Rubber Tip Air Nozzle. Transmission fluid will immediately start flowing out of the Fluid Transporter/Evacuator/Injector into the transmission fluid pan. 8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the Rubber Tip Air Nozzle from the end of the hose. 9. NOTE: Engine idle speed is approximately 650 rpm. Using the scan tool, start and run the engine until the Transmission Fluid Temperature (TFT) is between 27°C-49°C (80°F-120°F). 10. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. If the fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 9 and 10. 11. Once the transmission is full, place a hand Vacuum Pump Kit on the open end of the vacuum/pressure hose on the Fluid Transporter/Evacuator/Injector and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 12. Allow the transmission fluid to drain. When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1467 13. Reinstall the small (center) transmission fluid level indicating plug. - Tighten to 10 Nm (89 lb-in). Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning NOTICE: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or Oil-To-Air (OTA), if equipped, will need to be installed. Failure to follow these instructions may result in transmission failure. NOTICE: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler tubes, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler tubes as described. Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube). - Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. 6. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission cooler return tube) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1468 Fluid - A/T: Service and Repair 6R80 Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Drain 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Some transmission fluid leakage may occur when removing the transmission fluid fill plug. Remove the transmission fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1469 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket, if required. 5. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. - Tighten to 12 Nm (106 lb-in). Transmission Fluid Refill NOTICE: This procedure contains the air purge steps required to purge air from the transmission fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. NOTICE: The transmission fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTICE: 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 transmission fluid leaking, the transmission 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 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 fluid cooling system. - Fill the transmission fluid to the fill range on the transmission 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 transmission fluid added to the transmission as an initial fill if: - the transmission has been overhauled. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1470 - a new mechatronic assembly has been installed. - the transmission fluid pan or transmission fluid filter have been removed. Using the Transmission Fluid Fill Tube, add 3.3L (3.5 qt) of transmission fluid to the transmission through the transmission fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in this procedure. 2. Check the transmission fluid level cold. - 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 with the engine running, place the selector lever in each gear position and hold approximately 5 seconds. Place the selector lever in PARK, with the engine at idle (600-750 rpm). 3. Separate the transmission fluid level indicator from the transmission fluid fill plug. 4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 5. Add transmission fluid to the cold level location as shown in the illustration. 6. Install the transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). 7. While driving the vehicle, use the scan tool to verify that the Transmission Fluid Temperature (TFT) has reached a temperature of 88°C (190°F). This will circulate the transmission fluid through the torque converter and the transmission fluid cooling system, eliminating any trapped air in the transmission fluid cooling system. With the engine idling (600-750 rpm) in PARK, verify that the TFT is between 80°C-85°C (175°F-185°F). 8. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1471 9. Separate the transmission fluid level indicator from the transmission fluid fill plug. 10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 11. Using the scan tool verify that the TFT is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark. 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 transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). Adding Additional Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. Install the Transmission Fluid Fill Tube into the transmission fluid fill hole. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1472 2. Fill the Transporter Fluid Evacuator/Injector with approximately 0.47L (1 pt) of transmission fluid. 3. Hang the Transporter Fluid Evacuator/Injector under the vehicle, upright and close to the transmission. 4. Connect the Transporter Fluid Evacuator/Injector and Transmission Fluid Fill Tube. - Connect the open end of the fluid hose from the Transporter Fluid Evacuator/Injector onto the Transmission Fluid Fill Tube from the transmission case. 5. Use a Rubber Tip Air Nozzle to apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the Transporter Fluid Evacuator/Injector. Transmission fluid will immediately start flowing out of the Transporter Fluid Evacuator/Injector into the transmission. 6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1473 7. Using the scan tool, verify that the TFT is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark. 8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this procedure. Install the transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). Removing Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the Transporter Fluid Evacuator/Injector and the Vacuum Pump Kit to extract any excessive transmission fluid. 2. Using the scan tool, verify that the TFT is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 3. Install the transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1474 Transmission Fluid Exchange Transmission Fluid Exchange NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products can cause internal transmission components to fail, which will affect the operation of the transmission. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid. 3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission fluid cooler tube after the transmission fluid cooler on the return tube. This will help remove any foreign material trapped in the transmission fluid coolers. 4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Follow the manufacturer's instructions included with the machine. 5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Reconnect any disconnected transmission fluid cooler tubes. 6. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. Transmission Fluid Level Check Transmission Fluid Level Check Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1475 NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. NOTICE: The transmission 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 transmission fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. NOTE: If the installation of a new transmission fluid cooler or transmission fluid cooler tubes has 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 transmission fluid 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. 3. Remove the transmission fluid fill plug transmission fluid level indicator assembly, located on the passenger side front portion of the transmission case. 4. Separate the transmission fluid level indicator from the transmission fluid fill plug. 5. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 1476 6. Using the scan tool, verify that the Transmission Fluid Temperature (TFT) is between 80°C-85°C (175°F-185°F). Do not overfill the transmission. The transmission 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. For additional information, refer to Transmission Fluid Drain and Refill See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1481 Fluid - Differential: Fluid Type Specifications Front Differential Front Differential Dana 30.............................................................................................................................................M otorcraft SAE 80W-90 Premium Rear Axle Lubricant Part Number......................................................................................................................................... ..XY-80W90-QL(US) / CXY-80W90-1L(CANADA) Specification......................................................................................................................................... .........................................................WSP-M2C197-A Rear Differential Rear Differential Ford 8.8 Inch Ring Gear.................................................................................................................Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant Part Number......................................................................................................................................X Y-75W-140-QL(US) / CXY-75W140-1L(CANADA) Specification......................................................................................................................................... ........................................WSL-M2C192-A and GL-5 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ....................................................................................................................... ................................................. 1.5 Quarts (1.4 Liters) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1486 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid.............................................................................................................................. ...................................Motorcraft Transfer Case Fluid Part Number......................................................................................................................................... ...........................................................................XL-12 Specification......................................................................................................................................... ..........................................................ESP-M2C166-H Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1487 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling 1. NOTICE: Transfer case failure can result if the correct fill procedures are not followed. NOTE: Position a suitable drain pan under the transfer case. Remove the drain plug and drain the fluid. 2. Clean and install the drain plug. - Tighten to 20 Nm (177 lb-in). 3. NOTICE: Incorrect fluid fill can result in transfer case failure. NOTE: Fill the transfer case with the vehicle on a level surface. Make sure the fluid is level with the filler opening for the correct fluid level. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications Engine Oil: Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering Fluid Type Ford Part Name ................................................................................................................................... ................................ Motorcraft MERCON V ATF Ford Part Number ................................................. ............................................................................................................................................. XT-5-QM Ford Specification ................................................................................................................................ ......................................................... MERCON V Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...........................................................................................................................(0.77 kg) (27 oz) (1.7 lb) (vehicles without auxiliary systems) Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...................................................................................................................(1.25 kg) (44 oz) (2.75 lb) (vehicles with auxiliary climate control) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1498 Refrigerant: Fluid Type Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...........................................................................................................................(0.77 kg) (27 oz) (1.7 lb) (vehicles without auxiliary systems) Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...................................................................................................................(1.25 kg) (44 oz) (2.75 lb) (vehicles with auxiliary climate control) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1499 Refrigerant: Testing and Inspection Refrigerant Identification Testing Refrigerant Identification 1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the sample for testing. 2. The Refrigerant Blend Identifier with Printer will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital display. - If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light, "Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or greater. The Refrigerant Blend Identifier with Printer eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the scan tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. Contaminated Refrigerant Handling NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered refrigerant supply and may damage the recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system flushing procedure. 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. - If this equipment is not available, contact an A/C service facility in the area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the A/C system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant: Service and Repair Air Conditioning (A/C) System Recovery, Evacuation and Charging Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant System Recovery NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1502 facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and instructions. NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment that meets the requirements of the SAE J2788 standard. NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery. If a R-134a Refrigerant Management Machine is not available, refrigerant system recovery may be accomplished using a separate recovery station. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer to Refrigerant Identification Testing See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics/Refrigerant Identification Testing. 2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. Note the amount of oil removed during the refrigerant recovery (if any). Add that same amount back into the system once repairs are complete. 4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery, evacuation and charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes. 3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out evacuation of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the Vacuum Pump. 3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1503 4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service gauge port valves) and turn OFF the Vacuum Pump. 6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding. 2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant Charging Meter NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding. 2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a supply tank following the Automatic Refrigerant Charging Meter operating instructions. 3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select MAX A/C operation and allow the refrigerant charge to complete. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1504 Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation WARNING: Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury. NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer's procedures and instructions. NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any foreign material. These components are typically discarded after A/C system contamination. Hoses without mufflers can normally be reused unless they are clogged with foreign material. The filter is intended for use on one vehicle only. 1. Orient the filter inlet toward the A/C condenser core. 2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for low-pressure flushing and are not designed for use with a charged refrigerant system. Do not make the condenser fitting connections using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur. NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the end of this procedure. Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2 halves of the fitting. - Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. - Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush and Purge Fitting Kit. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 1505 3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding. 4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C operation and set the blower motor speed to maximum. Start the engine and let it idle briefly. Make sure the A/C system is operating correctly. 7. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C system operating. 8. Stop the engine. 9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the condenser to evaporator tube. 11. Discard the pancake filter. It can be used one time only. 12. Reconnect the condenser outlet fitting. 13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair Refrigerant Oil: Service and Repair Refrigerant Oil Adding Refrigerant Oil Adding NOTE: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the PAG oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Refer to the chart below for refrigerant oil adding amounts and methods of installation. a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the total system PAG oil capacity must be added. b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the PAG oil amount by the number of O-ring leaks being repaired. Adding Refrigerant Oil After A/C Compressor Replacement Service A/C compressors shipped without clutch and pulley 1. Rotate the A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 oz), pour the same amount plus 30 ml (1 oz) of clean PAG Refrigerant Compressor Oil (R-134a Systems) (YN-12-D) WSH M1C231-B or equivalent into the new A/C compressor. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Page 1509 - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 oz), pour 85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. Service A/C compressors shipped with clutch and pulley 2. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml (4 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 118 ml (4 oz), remove 59 ml (2 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 148 ml (5 oz), remove 29 ml (1 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0 ml (0 oz) from the new A/C compressor. Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or TXV have also been installed due to system contamination, refer to the appropriate heading. 1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and 60 ml (2 fl oz). Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system contamination and the A/C system has been flushed. NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port. 2. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during system charging. For the total PAG oil capacity specification, refer to the Specifications table. Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the PAG oil. 1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On Injector Kit-Set to match the amount of refrigerant compressor oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. 4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Service and Repair > Page 1510 5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set. 6. Open all valves and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Master Cylinder Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder is installed, or the system is emptied or partially emptied, it should be primed to prevent air from entering the system. 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake master cylinder reservoir with clean, specified brake fluid. 4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 5. Remove the short brake tubes and install the brake outlet tubes. 6. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 2. Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1515 tighten 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. 5. Tighten the brake tube fittings to specifications. For additional information, refer to Specifications. 7. Bleed the brake system, refer to Brake System Bleeding See: Brake System Bleeding. Brake Caliper Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1516 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1517 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Pressure WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the equipment manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1518 4. Open the valve on the bleeder tank. - Set pressure to 207-345 kPa (30-50 psi). 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. Tighten to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw ending with the LH front bleeder screw. 7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter from the brake fluid reservoir. Manual WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Remove the bleeder screw cap and place a box-end wrench on the RH rear bleeder screw. Attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 1519 3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order. Hydraulic Control Unit (HCU) NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system. 2. Connect the scan tool and follow the ABS Service Bleed instructions. 3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. 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 this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagram. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition to OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1524 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1525 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the cover and RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1526 7. Remove the 2 driver air bag module bolts (1 shown). 8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Open and lower the glove compartment door. 10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield. 11. NOTE: The canister vent and adaptive tether do not require deactivation. Disconnect the LH side passenger air bag module electrical connector. 12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Disengage the passenger seat side air bag module electrical connector locking clip, release the tab and disconnect the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 13. Release and position aside the passenger side C-pillar trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1527 14. Disconnect the passenger side safety canopy module electrical connector. 15. Release and position aside the driver side C-pillar trim panel. 16. Disconnect the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 17. Remove the driver and passenger side upper C-pillar trim panels. 18. Disconnect the passenger side safety canopy module electrical connector. 19. Disconnect the driver side safety canopy module electrical connector. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1528 20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module electrical connector locking clip, release the tab and disconnect the driver seat side air bag module electrical connector. 21. Install the RCM fuse 17 (10A) to the SJB. 22. 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. 3. Connect the driver seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles 4. Connect the driver side safety canopy module electrical connector. 5. Connect the passenger side safety canopy module electrical connector. 6. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 7. Connect the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1529 8. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 11. Connect the passenger seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Attach the passenger seat side air bag module electrical connector to the seat track bracket. 12. Connect the LH side passenger air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 1530 13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer. 14. NOTICE: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. 15. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 16. Turn the ignition switch from OFF to ON. 17. Install RCM fuse 17 (10A) to the SJB and install the cover. 18. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 19. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1535 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1536 Circuit Breaker: Application and ID Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1537 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1542 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1543 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1544 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1545 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1546 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1547 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1548 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1549 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1550 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1551 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1554 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1555 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1556 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1557 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1558 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1559 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1560 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1561 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1562 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 1563 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) Fuse Block: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1568 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1569 Fuse Block: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1570 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1571 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1572 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1573 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 1574 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1577 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1579 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1580 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1581 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1582 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1583 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1584 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1585 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1587 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1588 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1589 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1590 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1591 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1592 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1593 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1594 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1595 Fuse Block: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1596 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1597 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1598 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1599 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1600 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1601 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) Relay Box: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 1606 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 1607 Relay Box: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 1608 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 1609 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 1610 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 1611 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 1612 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1615 Relay Box: Diagrams Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1616 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1617 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1618 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1619 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 1620 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 1623 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 1624 Relay Box: Application and ID Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 1625 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures Maintenance Required Lamp/Indicator: Procedures Message Center Configuration Oil Life Reset And Start Value - High Series Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Base Instrument Cluster NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 1631 Maintenance Required Lamp/Indicator: Reset Procedure Oil Life Reset and Start Value - With Message Center Message Center Configuration Oil Life Reset And Start Value - With Message Center NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset and Start Value - Without Message Center Message Center Configuration Oil Life Reset And Start Value - Without Message Center NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The 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 four 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 three 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/No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index. - 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 ignition in the RUN position (engine not running) if DTC P1000 is set. CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. WARNING: Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure to follow this instruction may result in serious personal injury. NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. NOTICE: When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage to the axle carrier or rear cover. NOTICE: 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. Jacking Points Lifting Points Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1639 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training 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). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Tire Monitoring System/Testing and Inspection/Programming and Relearning. 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. 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1645 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. 8. 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. 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. 10. 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1646 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 2. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. 3. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1649 4. Remove the sensor. Assembly 1. NOTICE: Damage to the sensor may 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. 3. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 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 See: Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1650 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor See: Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1651 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory-installed strap in the following 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 in) from the buckle. 2. Using a large screwdriver and a twisting motion, unbuckle the strap. 3. Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. - Discard the strap. 4. 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. NOTICE: Metal scrapers may 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. Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed. 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 degrees from the valve stem. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1652 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. NOTICE: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. 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 in) away from the sensor and tighten the worm gear. - Tighten to 3 Nm (27 lb-in). 6. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire. See: Service and Repair/Overhaul 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. See: Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training 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). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Testing and Inspection/Programming and Relearning. 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. 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1658 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. 8. 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. 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. 10. 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1659 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 2. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. 3. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1662 4. Remove the sensor. Assembly 1. NOTICE: Damage to the sensor may 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. 3. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 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 See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1663 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor See: Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1664 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory-installed strap in the following 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 in) from the buckle. 2. Using a large screwdriver and a twisting motion, unbuckle the strap. 3. Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. - Discard the strap. 4. 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. NOTICE: Metal scrapers may 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. Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed. 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 degrees from the valve stem. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1665 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. NOTICE: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. 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 in) away from the sensor and tighten the worm gear. - Tighten to 3 Nm (27 lb-in). 6. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire. See: Service and Repair/Overhaul 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. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1674 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-1 > Jul > 09 > Wheels - 17 Inch Polished Wheel Clearcoat Cracking > Page 1679 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1685 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > 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 1690 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1696 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1697 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1703 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1704 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1709 2. Remove and discard the halfshaft nut. - To install, tighten the new nut to 250 Nm (184 lb-ft). 3. Using the Front Wheel Hub Remover, separate the outboard CV joint from the wheel hub. 4. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 bolts and the wheel bearing and hub assembly. - Discard the bolts. - To install, tighten the new bolts to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1710 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. 2. Remove the 3 brake disc shield bolts. - To install, tighten to 8 Nm (71 lb-in). 3. Using the Bearing Puller and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1711 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. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1720 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 1726 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1732 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1733 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1739 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Cover: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 1740 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft nut....................................................................................................................... ........................................................................250 Nm (184 lb-ft) Rear Drive Halfshaft nut....................................................................................................................... ........................................................................275 Nm (203 lb-ft) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications NOTICE: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts, using the pattern indicated, to..............................................................................................................................135 Nm (100 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) Wheel Fastener: Service and Repair Front Suspension - Rear Wheel Drive (RWD) Wheel Studs Removal 1. Remove the wheel and tire. 2. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft). 3. Remove the brake disc. 4. Using the C-Frame and Screw, remove the wheel stud. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1750 Installation 1. NOTICE: 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. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange. Install approximately 4 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 (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1751 Wheel Fastener: Service and Repair Rear Suspension Wheel Studs Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed, or incorrect clamp load and component damage may occur. 1. Remove the wheel and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1752 2. NOTICE: 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. NOTICE: 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. NOTE: 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 C-Frame and Screw, press the wheel stud until it makes contact with the edge of the wheel knuckle. 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. NOTICE: 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. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange. Place approximately 4 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. NOTICE: A plug must be installed in place of the knockout to prevent contamination to the parking brake shoe assemblies. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 1753 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 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. WARNING: Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure to follow this instruction may result in serious personal injury. NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. NOTICE: When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage to the axle carrier or rear cover. NOTICE: 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. Jacking Points Lifting Points Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 1757 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are four 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 four 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. The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection section. For additional information, refer to the Engine System - General Information. Verification of incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General Information. Variable Camshaft Timing (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 indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), engine coolant temperature (ECT), engine oil temperature (EOT), CMP, throttle position (TP), mass air flow (MAF), and CKP sensors 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 1764 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. 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 two 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. VCT System Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1 > Page 1769 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 > Page 1772 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams > Page 1773 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 Variable Camshaft Timing (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 (V6-4.0L (2009)) 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1777 Compression Check: Testing and Inspection Engine 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 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1778 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 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 within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Position the camshaft bearing caps and the 8 bolts for each set of camshaft bearing caps. Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to....................................................... ...................................................................................................................................6 Nm (53 lb-in). Stage 2: Tighten to............................................................................................................................... .......................................................16 Nm (142 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Tighten the camshaft bolt to................................................................................................................. ..........................................................85 Nm (63 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures Camshaft Journal To Bearing Clearance - OHC Engines Camshaft Journal to Bearing Clearance - OHC Engines NOTE: Refer to the Engine system level for the specification. 1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. Measure each camshaft bearing in 2 directions. - Subtract the camshaft journal diameter from the camshaft bearing diameter. Camshaft End Play - OHC Engines Camshaft End Play - OHC Engines NOTE: Refer to the Engine system level for the specification. 1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play. 2. Position the camshaft to the rear of the cylinder head. 3. Zero the Dial Indicator Gauge. 4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. - If camshaft end play exceeds specifications, install a 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1790 Camshaft Bearing Journal Diameter Camshaft Bearing Journal Diameter NOTE: Refer to the Engine system level for the specification. 1. Measure each camshaft journal diameter in 2 directions. Camshaft Lobe Lift Camshaft Lobe Lift NOTE: Refer to the Engine system level for the specification. 1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. - Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading to figure the camshaft lobe lift. Camshaft Runout Camshaft Runout Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1791 NOTE: Refer to the Engine system level for the specification. 1. NOTE: Camshaft journals must be within specifications before checking runout. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout. - Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading. Camshaft Timing Camshaft Timing Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1792 1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Camshaft Roller Follower. 2. If necessary, rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1793 3. If necessary, remove the 3 bolts and position the generator aside. 4. If necessary, remove the 4 bolts and position the A/C compressor and power steering pump bracket aside. 5. NOTE: The LH and RH camshafts must be retimed when either camshaft is disturbed. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC). 6. Remove the nut and position the wiring harness aside. 7. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crankshaft sensor speed wheel and incorrect timing of the engine. NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block. This positions the engine at TDC. Install the Crankshaft TDC Timing Tool. 8. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 to the RH cylinder head and tighten the 2 top clamp bolts to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1794 9. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, loosen the RH camshaft sprocket bolt. 10. Loosen the top 2 Camshaft Sprocket Holding Tool clamp bolts. 11. NOTE: The camshaft timing slots are off-center. Position the camshaft timing slots below the centerline of the camshaft and install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the RH cylinder head. 12. Remove the RH hydraulic timing chain tensioner. - Discard the washer. 13. Install the Timing Chain Tensioner. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1795 14. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. Tighten the bolts. 1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in). 2. Calculate the correct torque wrench setting for the following torque. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt to 85 Nm (63 lb-ft). 15. Remove the Timing Chain Tensioner. 16. NOTE: Install a new washer on the tensioner. Install the RH hydraulic timing chain tensioner. - Tighten to 44 Nm (32 lb-ft). 17. Remove the Camshaft Holding Tool, the Adapter for 303-577, the Camshaft Sprocket Holding Tool and the Adapter for 303-564 from the RH cylinder head. 18. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1796 19. Loosen the LH camshaft sprocket bolt. 20. Loosen the top 2 clamp bolts on the Camshaft Sprocket Holding Tool to allow the camshaft sprocket to rotate freely. 21. NOTE: The camshaft timing slots are off-center. Position the camshaft timing slots below the centerline of the camshaft and install the Camshaft Holding Tool and the Adapter for 303-577 on the rear of the LH cylinder head. 22. Remove the LH hydraulic timing chain tensioner. - Discard the washer. 23. Install the Timing Chain Tensioner. 24. Tighten the bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1797 1. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 10 Nm (89 lb-in). 2. Tighten the LH camshaft bolt to 85 Nm (63 lb-ft). 25. Remove the Timing Chain Tensioner. 26. NOTE: Install a new washer on the tensioner. Install the LH hydraulic timing chain tensioner. - Tighten to 44 Nm (32 lb-ft). 27. Remove the Camshaft Holding Tool, the Adapter for 303-577, the Camshaft Sprocket Holding Tool and the Adapter for 303-564 from the LH cylinder head. 28. Remove the Crankshaft TDC Timing Tool. 29. Position the battery cable bracket and install the nut. - Tighten to 20 Nm (177 lb-in). 30. If necessary, position the A/C compressor and power steering pump bracket and install the 4 bolts. - Tighten to 42 Nm (31 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1798 31. If necessary, position the generator and install the 3 bolts. - Tighten to 47 Nm (35 lb-ft). 32. If necessary, rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt. 33. Install the camshaft roller followers. For additional information, refer to Camshaft Roller Follower See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Camshaft Roller Follower. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1799 Camshaft: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View Accessory Drive Belt and Wiring Harness Bracket A/C Compressor and Power Steering Pump Bracket Valve Train Components - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1800 Valve Train Components - LH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1801 1. For additional information, refer to the procedures. Camshafts Camshafts Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1802 Removal Both sides 1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Camshaft Roller Follower. 2. Remove the nut and position the wiring harness bracket aside. 3. NOTE: Carry out the RH and LH camshaft timing procedure when either camshaft is serviced. Rotate the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC). 4. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crankshaft sensor speed wheel and incorrect timing of the engine. NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block. This positions the piston at TDC. Install the Crankshaft TDC Timing Tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1803 RH side 5. Remove the RH hydraulic timing chain tensioner. - Discard the washer. 6. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the rear of the RH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 lb-in). 7. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. Using the Torque Wrench Extension and the Camshaft Sprocket Nut Socket, loosen the camshaft sprocket bolt. 8. Remove the bolt and position the camshaft sprocket aside. LH side 9. Remove the LH hydraulic timing chain tensioner. - Discard the washer. 10. Rotate the accessory drive belt tensioner counterclockwise and detach the accessory drive belt from the A/C compressor and power steering pump pulleys. 11. Remove the bolts and position the A/C compressor and power steering pump bracket aside. 12. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH camshaft and tighten the 2 top clamp bolts to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1804 13. Remove the bolt and position the camshaft sprocket aside. Both sides 14. NOTE: Mark the position of the camshaft bearing caps so they can be installed in their original positions. Remove the 8 bolts for each set of camshaft bearing caps in the sequence shown and remove the camshaft bearing caps. 15. Remove the camshaft. Installation NOTE: Lubricate the camshaft journal bearing surfaces on the cylinder head, the camshaft journals and the camshaft bearing caps with clean engine oil. Both sides 1. Install the camshaft. 2. NOTE: The camshaft bearing caps must be installed in their original positions. NOTE: After installing the bolts, check the camshaft for free rotation. Position the camshaft bearing caps and the 8 bolts for each set of camshaft bearing caps. - Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to 6 Nm (53 lb-in). - Stage 2: Tighten to 16 Nm (142 lb-in). RH side 3. NOTICE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt may result in incorrect engine timing. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. Install the camshaft sprocket and loosely install the bolt. LH side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 1805 4. NOTICE: The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time. Tightening the bolt may result in incorrect engine timing. Install the camshaft sprocket and loosely install the bolt. Both sides 5. Time the camshafts. For additional information, refer to Camshaft Timing See: Procedures/Camshaft Timing. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures Lifter / Lash Adjuster: Procedures Hydraulic Lash Adjuster Inspection 1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1810 Lifter / Lash Adjuster: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View Accessory Drive Belt and Wiring Harness Bracket A/C Compressor and Power Steering Pump Bracket Valve Train Components - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1811 Valve Train Components - LH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1812 1. For additional information, refer to the procedures. Hydraulic Lash Adjuster Hydraulic Lash Adjuster Removal and Installation 1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Camshaft Roller Follower. 2. NOTE: Mark each hydraulic lash adjuster to make sure it is returned to its original position. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1813 Remove the hydraulic lash adjusters. 3. NOTE: The hydraulic lash adjusters must be installed in their original positions. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Roller Follower Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1818 Rocker Arm Assembly: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View Accessory Drive Belt and Wiring Harness Bracket A/C Compressor and Power Steering Pump Bracket Valve Train Components - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1819 Valve Train Components - LH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1820 1. For additional information, refer to the procedures. Camshaft Roller Follower Camshaft Roller Follower Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1821 Removal and Installation 1. Remove the LH and RH valve covers. For additional information, refer to Valve Cover - RH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - RH and Valve Cover - LH See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Cover - LH. 2. Remove the fuel rail. 3. Remove the cooling fan. 4. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle. 5. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position. Using the Valve Spring Compressor, remove the camshaft roller followers. 6. NOTE: The camshaft roller followers must be installed in their original positions. NOTE: Lubricate the camshaft roller followers with clean engine oil. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are four 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 four 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. The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection section. For additional information, refer to the Engine System - General Information. Verification of incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General Information. Variable Camshaft Timing (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 indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), engine coolant temperature (ECT), engine oil temperature (EOT), CMP, throttle position (TP), mass air flow (MAF), and CKP sensors 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 1825 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. 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 two 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. VCT System Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Cover / Housing > Component Information > Service and Repair Variable Valve Timing Cover / Housing: Service and Repair Variable Camshaft Timing (VCT) Housing Cleaning and Inspection 1. Remove the screw and the Variable Camshaft Timing (VCT) oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 2. Clean the mating surfaces and oil passages with metal surface prep. Follow the directions on the packaging. 3. Inspect the VCT housing for pitting, cracks or damaged sealing surfaces. Install a new VCT housing if damaged. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1833 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1834 Connecting Rod Bearing: Service and Repair Bearing Inspection 1. Inspect bearings for the following defects: 1. Cratering - fatigue failure 2. Spot polishing - incorrect seating 3. Imbedded dirty 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING ROD Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1838 ROD BEARING CAP Tighten the 2 connecting rod nuts in 2 stages. Stage 1: Tighten to..................................................... .................................................................................................................................20 Nm (177 lb-in). Stage 2: Tighten an additional.............................................................................................................. ...................................................................90 degrees. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round Connecting Rod: Service and Repair Connecting Rod Bearing Journal Taper and Out-of-Round Connecting Rod Bearing Journal Taper and Out-of-Round NOTE: Refer to the Engine system level for the specification. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1841 Connecting Rod: Service and Repair Connecting Rod Bearing Journal-to-Bearing Clearance Connecting Rod Bearing Journal-to-Bearing Clearance NOTE: Refer to the Engine system level for the specification. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1842 Connecting Rod: Service and Repair Connecting Rod Bend Connecting Rod Bend NOTE: Refer to the Engine system level for the specification. 1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1843 Connecting Rod: Service and Repair Connecting Rod Bushing Diameter Connecting Rod Bushing Diameter NOTE: Refer to the Engine system level for the specification. 1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped. 2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1844 Connecting Rod: Service and Repair Connecting Rod Bearing Journal Taper and Out-of-Round Connecting Rod Bearing Journal Taper and Out-of-Round NOTE: Refer to the Engine system level for the specification. 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. Connecting Rod Bearing Journal-to-Bearing Clearance Connecting Rod Bearing Journal-to-Bearing Clearance NOTE: Refer to the Engine system level for the specification. 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. Connecting Rod Bend Connecting Rod Bend Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1845 NOTE: Refer to the Engine system level for the specification. 1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Connecting Rod Bushing Diameter Connecting Rod Bushing Diameter NOTE: Refer to the Engine system level for the specification. 1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped. 2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification. Connecting Rod Cleaning Connecting Rod Cleaning NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1846 Connecting Rod Large End Bore Connecting Rod Large End Bore NOTE: Refer to the Engine system level for the specification. 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. Connecting Rod to Crankshaft Side Clearance Connecting Rod to Crankshaft Side Clearance NOTE: Refer to the Engine system level for the specification. 1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification. Connecting Rod Twist Connecting Rod Twist Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Connecting Rod Bearing Journal Taper and Out-of-Round > Page 1847 NOTE: Refer to the Engine system level for the specification. 1. Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. Connecting Rod-to-Piston Clearance Connecting Rod-to-Piston Clearance NOTE: Refer to the Engine system level for the specification. 1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications MAIN BEARING CAP Tighten the 8 bolts in the sequence shown in 2 stages. Stage 1: Tighten to....................................... ..................................................................................................................................................35 Nm (26 lb-ft). Stage 2: Tighten an additional.............................................................................................. ...................................................................................57 degrees. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1851 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1852 Crankshaft Main Bearing: Service and Repair Bearing Inspection 1. Inspect bearings for the following defects: 1. Cratering - fatigue failure 2. Spot polishing - incorrect seating 3. Imbedded dirty 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Refer to the Engine system level for the specification. 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: Service and Repair Crankshaft Main Bearing Journal-To-Bearing Clearance Crankshaft Main Bearing Journal-to-Bearing Clearance NOTE: Refer to the Engine system level for the specification. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1859 Crankshaft: Service and Repair Crankshaft End Play Crankshaft End Play NOTE: Refer to the Engine system level for the specification. 1. Install the Dial Indicator Gauge with Holding Fixture. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the Dial Indicator Gauge. 4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1860 Crankshaft: Service and Repair Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Diameter NOTE: Refer to the Engine system level for the specification. 1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair/Procedures/Cooling System Draining, Filling and Bleeding. 3. Disconnect the block heater power cable. 4. NOTE: 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 4 Nm (35 lb-in). 5. Clean and inspect the engine block mating surface. Lubricate the block heater seal and the cylinder block hole with clean engine coolant. 6. NOTICE: Make sure the power cable is routed and secured away from rotating or hot components or the cable may be damaged. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Using the Strap Wrench, tighten the bolt in 2 stages. Stage 1: Tighten to........................................... ..............................................................................................................................................55 Nm (41 lb-ft). Stage 2: Rotate an additional................................................................................................ ...................................................................................85 degrees. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1867 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the fan shroud. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1868 3. Remove the accessory drive belt. 4. NOTE: This bolt is torque-to-yield and cannot be reused. Using the Strap Wrench to hold the crankshaft pulley, remove the bolt. 5. NOTE: If the pulley bolt is not installed, the tool will bottom out before the pulley is off. Install the crankshaft pulley bolt 2 to 3 turns. Using the 2 Crankshaft Vibration Damper Removers and the two 8-mm bolts, remove the crankshaft pulley. - Discard the crankshaft pulley bolt. Installation 1. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley. 2. Using the Strap Wrench to hold the crankshaft pulley, install a new crankshaft pulley bolt. Tighten the bolt in 2 stages. - Stage 1: Tighten to 55 Nm (41 lb-ft). - Stage 2: Tighten an additional 85 degrees. 3. Install the accessory drive belt. 4. Install the fan shroud. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1872 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTICE: 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 Bore Diameter Piston Pin Bore Diameter NOTE: Refer to the Engine system level for the specification. 1. 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. Piston Diameter Piston Diameter NOTE: Refer to the Engine system level for the specification. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1875 1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the top of the piston at the point indicated. Piston To Cylinder Bore Clearance Piston To Cylinder Bore Clearance NOTE: Refer to the Engine system level for the specification. 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. 2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on their relative position within the range. A paint spot or specific size grade on a new piston indicates the position within the size range. Choose the piston with the correct paint color or specific size grade. Piston Ring End Gap Piston Ring End Gap NOTICE: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1876 NOTE: Piston rings should not be transferred from one piston to another. NOTE: Refer to the Engine system level for the specification. NOTE: The 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 the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end gap. Piston Ring-To-Groove Clearance Piston Ring-to-Groove Clearance NOTE: Refer to the Engine system level for the specification. 1. Inspect the piston for ring land damage or accelerated wear. 2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance. Piston Pin Diameter Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1877 Piston Pin Diameter NOTE: Refer to the Engine system level for the specification. 1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1878 Piston: Overhaul Piston Disassembly NOTE: The connecting rod bolts and nuts cannot be reused. NOTE: Mark the position of the parts, so they can be installed in their original positions. 1. Remove the connecting rod bearings from the connecting rod and cap. 2. Remove the piston rings from the piston. 3. Using the Piston Pin Service Set, press the piston pin out of the connecting rod and piston assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1879 Assembly NOTE: Lubricate all parts with clean engine oil. NOTE: Install the piston in the connecting rod with the cylinder number side of the rod and the indentation notch in the piston on the same side. NOTE: The oil hole in the connecting rod must face the RH side of the cylinder block and the arrow on the piston must face the front of the engine block. 1. NOTE: If the piston pin is removed from the piston, a new piston and piston pin must be used. Do not reuse the piston or the piston pin. Gradually heat the pin bore side of the connecting rod to approximately 232°C-316°C (467°F-626°F) and immediately install the piston pin. 2. Using the Piston Pin Service Set, press the piston pin into the piston and connecting rod assembly. 3. Install the piston rings. 4. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston. 5. Install the connecting rod bearings in the connecting rod and cap. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1883 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious 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. NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures Rocker Arm Assembly: Procedures Roller Follower Inspection 1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1892 Rocker Arm Assembly: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View Accessory Drive Belt and Wiring Harness Bracket A/C Compressor and Power Steering Pump Bracket Valve Train Components - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1893 Valve Train Components - LH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1894 1. For additional information, refer to the procedures. Camshaft Roller Follower Camshaft Roller Follower Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Procedures > Page 1895 Removal and Installation 1. Remove the LH and RH valve covers. For additional information, refer to Valve Cover - RH See: Valve Cover/Service and Repair/Valve Cover RH and Valve Cover - LH See: Valve Cover/Service and Repair/Valve Cover - LH. 2. Remove the fuel rail. 3. Remove the cooling fan. 4. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle. 5. NOTE: Mark each camshaft roller follower to make sure it is returned to its original position. Using the Valve Spring Compressor, remove the camshaft roller followers. 6. NOTE: The camshaft roller followers must be installed in their original positions. NOTE: Lubricate the camshaft roller followers with clean engine oil. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ignition and PCV Components, and Camshaft Position (CMP) Sensor LH Valve Cover Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1900 1. Remove the intake manifold. For additional information, refer to Intake Manifold See: Intake Manifold/Service and Repair. 2. Disconnect the Camshaft Position (CMP) sensor electrical connector. 3. Disconnect the ignition coil electrical connector. Detach the wiring harness retainer. 4. Disconnect the 3 fuel injector electrical connectors. Detach the wiring harness retainers. 5. Remove the PCV valve tube. 6. Disconnect the PCV valve electrical connector. 7. Detach the spark plug wire retainers. 8. Remove the 6 bolts and the valve cover. - To install, tighten to 10 Nm (89 lb-in). 9. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old valve cover gasket. Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1901 Valve Cover: Service and Repair Valve Cover - RH Valve Cover - RH Heater Hose Tube, Spark Plug Wires, Fuel Supply Tube and Crankcase Ventilation Tube RH Valve Cover Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Cover - LH > Page 1902 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Disconnect the spring lock coupling from the fuel supply tube. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. For additional information, refer to Intake Manifold See: Intake Manifold/Service and Repair. 4. Remove the heater hose tube bracket rear bolt. - To install, tighten to 23 Nm (17 lb-ft). 5. Remove the heater hose tube bracket front bolt. - To install, tighten to 34 Nm (25 lb-ft). 6. Loosen the exhaust manifold-to-EGR system module tube lower fitting and remove the tube. - To install, tighten to 34 Nm (25 lb-ft). 7. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring seals may cause the fuel system to leak. Remove the fuel supply tube-to-valve cover bracket bolt, the 4 fuel supply tube bolts and the fuel supply tube. Remove and discard the O-ring seals. - Install new O-ring seals and lubricate them with clean engine oil. - To install, tighten to 6 Nm (53 lb-in). 8. Detach the spark plug wire retainers and position the spark plug wires aside. 9. Remove the crankcase ventilation tube. 10. Remove the 6 bolts and the valve cover. - To install, tighten to 10 Nm (89 lb-in). 11. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches which make leak paths. Use a plastic scraping tool to remove all traces of the old valve cover gasket. Clean and inspect the sealing surfaces and the gasket. Install a new gasket if necessary. 12. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Valve Guide Inner Diameter NOTE: Refer to the Engine system level for the specification. 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 inside 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, install a new cylinder head assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve and Seat Refacing Measurements Valve Seat: Service and Repair Valve and Seat Refacing Measurements Valve Seat Inspection Valve and Seat Refacing Measurements NOTE: Refer to the Engine system level for the specification. NOTE: 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. Install a new cylinder head assembly if abnormalities are found. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve and Seat Refacing Measurements > Page 1910 Valve Seat: Service and Repair Valve Seat Width Valve Seat Width NOTE: Refer to the Engine system level for the specification. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Service and Repair > Valve and Seat Refacing Measurements > Page 1911 Valve Seat: Service and Repair Valve Seat Runout Valve Seat Runout NOTE: Refer to the Engine system level for the specification. 1. Use a valve seat runout gauge to check valve seat runout. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures Valve Spring: Procedures Valve Spring Installed Length Valve Spring Installed Length NOTE: Refer to the Engine system level for the specification. 1. Measure the installed length of each valve spring. Valve Spring Free Length Valve Spring Free Length NOTE: Refer to the Engine system level for the specification. 1. Measure the free length of each valve spring. 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. Valve Spring Strength Valve Spring Strength Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1916 NOTE: Refer to the Engine system level for the specification. 1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1917 Valve Spring: Removal and Replacement Valve Train Components - Exploded View Valve Train Components - Exploded View Accessory Drive Belt and Wiring Harness Bracket A/C Compressor and Power Steering Pump Bracket Valve Train Components - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1918 Valve Train Components - LH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1919 1. For additional information, refer to the procedures. Valve Springs Valve Springs Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Procedures > Page 1920 Removal and Installation 1. Remove the camshaft roller followers. For additional information, refer to Camshaft Roller Follower See: Rocker Arm Assembly/Service and Repair/Removal and Replacement/Camshaft Roller Follower. 2. Position the piston of the cylinder being serviced at Top Dead Center (TDC). 3. NOTICE: 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. Hold the valves in the cylinder head. - Remove the spark plug of the cylinder being serviced. - Use a suitable tool to apply air pressure to the cylinder. 4. Using the Valve Spring Compressor, remove the valve spring retainer keys, the valve spring retainers and the valve springs. 5. NOTE: Lubricate the valve springs, the retainers and the retainer keys with clean engine oil. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Refer to the Engine system level for the specification. 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 1925 Valve: Service and Repair Valve 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Valve Stem Diameter > Page 1926 Valve: Service and Repair Valve Stem To Valve Guide Clearance Valve Stem to Valve Guide Clearance NOTE: Refer to the Engine system level for the specification. NOTE: The 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 Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide. 2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Accessory Drive Belt Routing Front End Accessory Drive (FEAD) - 4.0L SOHC Front End Accessory Drive (FEAD) - 4.6L (3V) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt - Noise/Flutter Drive Belt: Testing and Inspection Drive Belt - Noise/Flutter Accessory Drive Drive Belt - Noise/Flutter NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may occur. 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. 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 (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic transmissions. - WOT 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. - the A/C anti-slugging strategy executes after a long hot heat soak. - 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 or idler pulley(s) 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt - Noise/Flutter > Page 1933 Drive Belt: Testing and Inspection Drive Belt - Incorrect Installation Accessory Drive Drive Belt - Incorrect Installation NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may 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 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 and wear, especially the mounting pad surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of alignment. Either of these conditions 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1936 Drive Belt: Service and Repair Accessory Drive Belt Accessory Drive Belt - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. To install, reverse the removal procedure. - For correct belt routing, refer to Accessory Drive See: Description and Operation, Accessory Drive Belt Routing, Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Belt Tensioner - Mechanical Drive Belt Tensioner: Testing and Inspection Belt Tensioner - Mechanical Accessory Drive Component Tests 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 Accessory Drive See: Description and Operation in the 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 from the tensioner. Carry out the following tests: - Using the 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. - Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition. - Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination and repair any leaks. 3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to testing the tensioner dynamically. 4. If the tensioner is saturated with oil and grease internally, install a new tensioner. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Belt Tensioner - Mechanical > Page 1941 Drive Belt Tensioner: Testing and Inspection Belt Tensioner - Dynamics Accessory Drive Component Tests 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 A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Drive Belt Tensioner: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1944 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Accessory Drive Belt Tensioner - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. Remove the bolt and the accessory drive belt tensioner. - To install, tighten the bolt to 47 Nm (35 lb-ft). 3. To install, reverse the removal procedure. - For correct belt routing, refer to Accessory Drive See: Description and Operation, Accessory Drive Belt Routing, Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures Engine Mount: Procedures Powertrain/Drivetrain Mount Neutralizing NOTE: Refer to the appropriate system and procedure for special instructions on loosening and tightening mount fasteners. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. NOTICE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may occur. Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same distance. 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1949 Engine Mount: Removal and Replacement Cylinder Block Cradle Cylinder Block Cradle Front End Components Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1950 Upper Cooling Fan Shroud Engine Support Insulator Bolt and Nut and Heater Tube Bracket Bolt Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1951 Stabilizer Bar and Crossmember Front Axle - Four-Wheel Drive (4WD) Vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1952 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the Air Cleaner (ACL) outlet tube. 4. Remove the starter. 5. Remove the oil pump screen and pickup tube. For additional information, refer to Oil Pump Screen and Pickup Tube See: Engine Lubrication/Oil Pick Up/Strainer/Service and Repair/Oil Pump Screen and Pickup Tube. 6. Remove the weatherstrip. 7. Remove the bolt and position the power steering fluid reservoir aside. 8. NOTICE: 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. Disconnect the coolant overflow hose. Remove the 2 bolts and the coolant expansion tank. 9. Remove the 2 bolts, unclip the clips and remove the upper fan shroud. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1953 10. Remove the heater tube bracket front bolt. 11. Install the Engine Lifting Bracket using the heater tube bracket front bolt. - Tighten to 23 Nm (17 lb-ft). 12. NOTE: This is not a typical setup. Only the right side of the engine will be raised. Install the Engine Support Bar and the 2 Adapters for 303-290A. All-Wheel Drive (AWD) vehicles 13. Remove the 4 bolts and the 2 stabilizer bar brackets. 14. Remove the 4 bolts and the crossmember. All vehicles 15. Remove the RH engine support insulator nut. 16. Remove the LH engine support insulator through bolt. 17. Remove the 2 transmission-to-cylinder block cradle bolts. 18. NOTE: Cylinder block cradle is shown removed for clarity. Note the location of the 2 Torx head bolts at the rear of the cylinder block cradle. Remove the 2 cylinder block cradle rear bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1954 19. Remove the 20 bolts and 2 nuts along the outside of the cylinder block cradle. 20. NOTE: Note the location of the 2 silver-colored bolts that have washer seals. They must be installed in the same position with new washer seals. Remove the 8 cylinder block cradle inner bolts and the 2 washer seals. - Discard the washer seals. 21. Raise the engine. AWD vehicles 22. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury. Support the front axle with a suitable jack. 23. Disconnect the vent hose from the axle housing vent tube. 24. NOTICE: Any time bolts, washers, spacers or nuts are loosened in the axle housing for any reason, install new components to prevent damage. Remove and discard the 3 axle housing bolts and 3 flagnuts. Lower the axle. All vehicles 25. Remove the cylinder block cradle. Installation All vehicles 1. NOTICE: Failure to back off the set screws may result in damage to the cylinder block cradle. Back the set screws off until they are below the cylinder block cradle boss. 2. NOTICE: 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 cylinder block cradle gasket and sealant. NOTE: Gasket material as well as silicone sealant may be present in the cavities in the main bearing cap. This material must be removed completely prior to assembly. Clean the gasket mating surfaces, making sure all the sealant is removed from the cavities on the rear main bearing cap. To clean the sealing area, use a plastic scraping tool, silicone gasket remover and metal surface prep. Follow the directions on the packaging. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1955 3. NOTE: If 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 may cause future oil leakage. Apply silicone in the 6 places shown. 4. Position a new gasket and the cylinder block cradle. Install the outer 20 bolts and 2 nuts finger-tight. 5. Install the 2 cylinder block cradle rear Torx bolts finger-tight. 6. Install the 2 transmission-to-cylinder block cradle bolts. - Tighten to 47 Nm (35 lb-ft). 7. Tighten the outer 20 bolts and 2 nuts. - Tighten the nuts to 10 Nm (89 lb-in). - Tighten the bolts to 14 Nm (124 lb-in). 8. Tighten the 2 cylinder block cradle rear Torx bolts. - Tighten to 10 Nm (89 lb-in). 9. Tighten the 8 inserts. - Tighten to 3 Nm (27 lb-in). 10. Install the 2 silver-colored bolts and new washer seals finger-tight. 11. Install the 6 remaining inner bolts finger-tight. 12. Tighten the 8 inner bolts in the sequence shown in 2 stages. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1956 - Stage 1: Tighten to 15 Nm (133 lb-in). - Stage 2: Tighten to 34 Nm (25 lb-ft). AWD vehicles 13. NOTICE: Any time bolts, washers, spacers or nuts are loosened in the axle housing for any reason, install new components to prevent damage. Raise the axle housing into position and install 3 new bolts and nuts. - Tighten to 66 Nm (49 lb-ft). 14. Connect the vent hose to the differential housing vent tube. All vehicles 15. Lower the engine and remove the Engine Support Bar and the Adapters for 303-290A. 16. Install the LH engine support insulator through bolt and nut. - Tighten to 103 Nm (76 lb-ft). 17. Install the RH engine support insulator nut. - Tighten to 90 Nm (66 lb-ft). AWD vehicles 18. Position the crossmember and install the 4 bolts. - Tighten to 103 Nm (76 lb-ft). 19. Position the 2 stabilizer bar brackets and install the 4 bolts. - Tighten to 55 Nm (41 lb-ft). All vehicles 20. Install the oil pump screen and pickup tube. For additional information, refer to Oil Pump Screen and Pickup Tube See: Engine Lubrication/Oil Pick Up/Strainer/Service and Repair/Oil Pump Screen and Pickup Tube. 21. Install the starter. 22. Remove the Engine Lifting Bracket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1957 23. Install the heater tube bracket front bolt. - Tighten to 34 Nm (25 lb-ft). 24. Position the upper fan shroud and install the 2 bolts. - Tighten to 7 Nm (62 lb-in). 25. Position the coolant expansion tank, install the 2 bolts and connect the coolant overflow hose. - Tighten to 7 Nm (62 lb-in). 26. Position the power steering fluid reservoir and install the bolt. - Tighten to 7 Nm (62 lb-in). 27. Install the weatherstrip. 28. Install the ACL outlet pipe. 29. Connect the battery ground cable. Engine Support Insulators Engine Support Insulators Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1958 Front End Components Upper Cooling Fan Shroud Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1959 Front Axle - Four-Wheel Drive (4WD) Vehicles RH Inner Fender Splash Shield Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1960 Engine Support Insulator - LH Engine Support Insulator - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1961 Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the weatherstrip. 4. Remove the bolt and position the power steering fluid reservoir aside. - To install, tighten to 7 Nm (62 lb-in). 5. NOTICE: 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. Disconnect the coolant overflow hose. Remove the 2 bolts and the coolant expansion tank. - To install, tighten to 7 Nm (62 lb-in). 6. Remove the 2 bolts, unclip the clips and remove the upper fan shroud. - To install, tighten to 7 Nm (62 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1962 7. Remove the bolt and install the Engine Lifting Bracket. - Tighten to 42 Nm (31 lb-ft). 8. Install the Engine Support Bar and the 2 Adapters for 303-290A. 9. Remove the LH engine support insulator through bolt. - To install, tighten to 103 Nm (76 lb-ft). 10. Remove the 5 pushpins and the RH inner fender splash shield. 11. Remove the 3 RH engine support insulator nuts. - To install, tighten to 90 Nm (66 lb-ft). 12. Raise the engine approximately 60 mm (2.36 in). 13. Remove the RH engine support insulator. All-Wheel Drive (AWD) vehicles 14. Remove the 4 bolts and the 2 stabilizer bar brackets. Allow the stabilizer bar to hang freely. - To install, tighten to 55 Nm (41 lb-ft). 15. WARNING: Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury. Support the axle housing with a suitable jack. 16. Disconnect the axle housing vent hose from the axle housing vent tube. 17. NOTICE: Any time bolts, washers, spacers or nuts are loosened in the axle housing for any reason, install new components to prevent damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Procedures > Page 1963 Remove and discard the 3 axle housing bolts and 3 flagnuts. Lower the axle housing approximately 25 mm (1 in). - To install, tighten to 66 Nm (49 lb-ft). All vehicles 18. Remove the nut and the LH engine support insulator. - To install, tighten to 90 Nm (66 lb-ft). 19. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View Idler Pulley: Service and Repair Front End Accessory Drive (FEAD) - Exploded View Front End Accessory Drive (FEAD) - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1968 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley Accessory Drive Belt Idler Pulley - 4.0L SOHC Removal and Installation 1. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt. 2. Remove the bolt and the accessory drive belt idler pulley. - To install, tighten to 47 Nm (35 lb-ft). 3. To install, reverse the removal procedure. - For correct belt routing, refer to Accessory Drive See: Description and Operation, Accessory Drive Belt Routing, Front End Accessory Drive (FEAD) - 4.0L SOHC in the Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure minimum at 2,000 rpm (engine at normal operating temperature)..............................................................................................103 kPa (15 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1973 Engine Oil Pressure: Testing and Inspection Engine Oil Pressure Test NOTICE: Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance history to make sure that the vehicle has not gone beyond the standard Ford recommended oil change intervals. Check the engine oil level and check the oil for contamination. If the oil is contaminated, engine damage can occur. The source of the contamination must be identified and repaired as necessary. 1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure port. 3. Run the engine until normal operating temperature is reached. 4. With the engine at idle record the gauge reading. 5. Run the engine at 2,000 rpm and record the gauge reading. 6. The oil pressure should be within specifications; refer to the specifications in the appropriate engine system. 7. If the pressure is not within specification, Go To Pinpoint Test B. See: Testing and Inspection/Pinpoint Tests/Pinpoint Test B: Low Oil Pressure Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Lubrication Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications Engine Oil: Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair Oil Cooler: Service and Repair Oil Cooler Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove and discard the oil filter. - To install, tighten to 13 Nm (115 lb-in). 4. Disconnect the oil cooler inlet hose from the oil cooler. 5. Disconnect the heater hose from the oil cooler. 6. Loosen the threaded insert and remove the oil cooler. - To install, tighten to 57 Nm (42 lb-ft). 7. To install, reverse the removal procedure. - Install a new oil filter. - Check the engine oil and fill as necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold - RH See: Exhaust System/Exhaust Manifold/Service and Repair/Removal and Replacement/Exhaust Manifold - RH. 3. Remove and discard the oil filter. - To install, tighten to 13 Nm (115 lb-in). Vehicles equipped with an oil cooler 4. NOTE: The oil cooler threaded insert is part of the oil cooler and is not removed. Loosen the oil cooler threaded insert and position the oil cooler aside. - To install, tighten to 57 Nm (42 lb-ft). All vehicles 5. Remove the bolt and the oil filter adapter. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 1986 - To install, tighten to 57 Nm (42 lb-ft). 6. To install, reverse the removal procedure. - Install a new oil filter. - Check the engine oil and fill as necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Install the gasket, the oil pan and the 10 bolts. Tighten to................................................................... ...................................................................................................................................11 Nm (97 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View Oil Pan: Service and Repair Engine Lubrication Components - Exploded View Engine Lubrication Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1992 Oil Pan: Service and Repair Oil Pan Oil Pan Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the drain plug and drain the engine oil. - To install, tighten to 26 Nm (19 lb-ft). 3. Remove the 10 bolts, the oil pan and the gasket. Discard the gasket. - To install, tighten to 11 Nm (97 lb-in). 4. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old oil pan gasket. Clean and inspect the sealing surfaces. 5. To install, reverse the removal procedure. 6. Fill the engine with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1996 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 1997 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View Oil Pick Up/Strainer: Service and Repair Engine Lubrication Components - Exploded View Engine Lubrication Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 2002 Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Oil Pump Screen and Pickup Tube Removal and Installation 1. Remove the oil pan. For additional information, refer to Oil Pan See: Oil Pan/Service and Repair/Oil Pan. 2. Remove the bolt and the oil pump screen and pickup tube. - To install, tighten to 10 Nm (89 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil pressure minimum at 2,000 rpm (engine at normal operating temperature)..............................................................................................103 kPa (15 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2007 Engine Oil Pressure: Testing and Inspection Engine Oil Pressure Test NOTICE: Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance history to make sure that the vehicle has not gone beyond the standard Ford recommended oil change intervals. Check the engine oil level and check the oil for contamination. If the oil is contaminated, engine damage can occur. The source of the contamination must be identified and repaired as necessary. 1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. 2. Connect the Oil Pressure Gauge to the oil pressure port. 3. Run the engine until normal operating temperature is reached. 4. With the engine at idle record the gauge reading. 5. Run the engine at 2,000 rpm and record the gauge reading. 6. The oil pressure should be within specifications; refer to the specifications in the appropriate engine system. 7. If the pressure is not within specification, Go To Pinpoint Test B. See: Testing and Inspection/Pinpoint Tests/Pinpoint Test B: Low Oil Pressure Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Control Components Engine Oil Temperature (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. Typical Thread Type Sensor Typical EOT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Intake Manifold: Specifications Intake Manifold Tighten to.............................................................................................................................................. ........................................................11 Nm (97 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold > Page 2015 Intake Manifold: Specifications Throttle Body Remove the 4 bolts, the TB and the gasket. Discard the gasket. To install, tighten to........................ .............................................................................................................................................................. ..9 Nm (80 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2016 Intake Manifold: Service and Repair Intake Manifold Intake Manifold Connections Intake Manifold Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2017 Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the battery ground cable. 3. Detach the Knock Sensor (KS) electrical connector from the intake manifold. 4. Disconnect the PCV tube from the intake manifold. 5. Disconnect the brake booster vacuum hose from the intake manifold. 6. Disconnect the main vacuum harness fitting from the intake manifold. 7. Disconnect the Evaporative Emission (EVAP) tube from the intake manifold. 8. Disconnect the EGR system module electrical connector. 9. Detach the wiring harness retainer. 10. Disconnect the EGR system module vacuum fitting. 11. Loosen the fitting and disconnect the exhaust manifold-to-EGR system module tube from the EGR system module. - To install, tighten to 34 Nm (25 lb-ft). 12. Disconnect the Throttle Position (TP) sensor electrical connector. 13. Disconnect the Electronic Throttle Body (ETB) electrical connector. 14. Remove the nut and detach the wiring harness bracket from the ETB. - To install, tighten to 9 Nm (80 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2018 15. Remove the 8 bolts, the intake manifold and the 6 gaskets. - To install, tighten to 11 Nm (97 lb-in). 16. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths. Use a plastic scraping tool to remove all traces of the old intake manifold gaskets. Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary. 17. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2023 Removal 1. Remove the flexplate. For additional information, refer to Flexplate See: Transmission and Drivetrain/Flex Plate/Service and Repair/Removal and Replacement. 2. Remove the spacer plate. 3. Remove the flexplate-to-crankshaft spacer. 4. NOTE: The original crankshaft rear seal does not have a metal speedy sleeve. Replacement rear crankshaft seals come with a speedy sleeve. If present, this sleeve must be removed before attempting to remove the seal. If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars. 5. NOTICE: Avoid scratching or damaging the crankshaft rear seal running surface during removal of the crankshaft rear seal. Scratches or other damage to the crankshaft may cause oil leaks. Using the Oil Seal Remover, remove the crankshaft rear seal. Installation 1. NOTE: The new replacement crankshaft rear seal comes with a speedy sleeve. The speedy sleeve must be installed with the crankshaft rear seal. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To clean the crankshaft rear seal surface area, use extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep. Lubricate the crankshaft rear oil seal with clean engine oil. 2. Install the Adapter for 303-579 and the Crankshaft Rear Oil Seal Screws. 3. Position the crankshaft rear seal with speedy sleeve on the Adapter for 303-579 and the Crankshaft Rear Oil Seal Screws. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2024 4. Using the Crankshaft Rear Oil Seal Installer, install the crankshaft rear seal with speedy sleeve. 5. Install the flexplate-to-crankshaft spacer. 6. Install the spacer plate. 7. Install the flexplate. For additional information, refer to Flexplate See: Transmission and Drivetrain/Flex Plate/Service and Repair/Removal and Replacement. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal 1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley See: Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair. 2. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal. Installation 1. NOTE: Lubricate the new front seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2028 Using the Front Cover Aligner and the Crankshaft Vibration Damper Installer, install a new crankshaft front seal. 2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley See: Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View Valve Guide Seal: Service and Repair Valve Train Components - Exploded View Valve Train Components - Exploded View Accessory Drive Belt and Wiring Harness Bracket A/C Compressor and Power Steering Pump Bracket Valve Train Components - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View > Page 2033 Valve Train Components - LH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View > Page 2034 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Valve Train Components - Exploded View > Page 2035 Valve Guide Seal: Service and Repair Valve Seals Valve Seals Removal 1. Remove the valve springs. For additional information, refer to Valve Springs See: Cylinder Head Assembly/Valve Spring/Service and Repair/Removal and Replacement/Valve Springs. 2. Remove the valve seals. Installation 1. NOTE: Lubricate the valve seals with clean engine oil. Using the Valve Stem Seal Installer, install the valve seal. 2. Install the valve springs. For additional information, refer to Valve Springs See: Cylinder Head Assembly/Valve Spring/Service and Repair/Removal and Replacement/Valve Springs. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2040 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2041 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Control Components Engine Oil Temperature (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. Typical Thread Type Sensor Typical EOT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Tighten the camshaft bolt to................................................................................................................. ..........................................................85 Nm (63 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams Timing Chain: Diagrams Early build vehicles NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position. Align the timing marks. - Install a 4 mm (0.16 in) pin to hold the shaft in place. Late build vehicles NOTE: Due to the gear ratio between the reversal shaft and the balance shaft, up to 7 complete turns of the balance shaft may be required to find the correct position. Align the timing marks. 1. Align the front balance shaft gear alignment marks with the hole in the balance shaft housing. 2. From the rear of the balance shaft, make sure the balance shaft gear alignment mark is visible through the hole in the balance shaft housing. All vehicles Install the balance shaft chain and crankshaft sprocket. Install the crankshaft key. Position the jackshaft and crankshaft sprockets and the chain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 2052 NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt. Loosely install the RH camshaft sprocket bolt. Position the LH camshaft sprocket. NOTE: The camshaft sprocket must turn freely on the camshaft. Do not tighten the bolt. Loosely install the LH camshaft sprocket bolt. Turn the crankshaft one revolution clockwise. NOTICE: Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine. NOTE: The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block. This positions the engine at Top Dead Center (TDC). Install the Crankshaft TDC Timing Tool. NOTE: Camshaft timing slots are off-center. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Diagrams > Page 2053 NOTE: Position the camshaft timing slots below centerline of camshaft. Install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the RH cylinder head. NOTE: Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the rear of the RH cylinder head. NOTICE: The RH camshaft sprocket bolt is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt. Tighten the bolts. NOTE: Do not tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts. The camshaft sprocket must rotate freely. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH cylinder head. NOTE: Camshaft timing slots are off-center. NOTE: Position the camshaft timing slots below centerline of camshaft. Install the Camshaft Holding Tool and the Adapter for 303-577 on the front of the LH cylinder head. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Install a new washer and the RH timing chain tensioner. Tighten to.................................................... ...................................................................................................................................................44 Nm (32 lb-ft). Install a new washer and the LH timing chain tensioner. Tighten to.................................................... ...................................................................................................................................................44 Nm (32 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Hydraulic Timing Chain Tensioner - LH Timing Chain Tensioner: Service and Repair Hydraulic Timing Chain Tensioner - LH Hydraulic Timing Chain Tensioner - LH Removal and Installation 1. Remove the hydraulic timing chain tensioner. - To install, tighten to 44 Nm (32 lb-ft). 2. Remove and discard the washer. 3. To install, reverse the removal procedure. - Install a new hydraulic timing chain tensioner washer. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Hydraulic Timing Chain Tensioner - LH > Page 2059 Timing Chain Tensioner: Service and Repair Hydraulic Timing Chain Tensioner - RH Hydraulic Timing Chain Tensioner - RH Removal and Installation 1. Remove the hydraulic timing chain tensioner. - To install, tighten to 44 Nm (32 lb-ft). 2. Remove and discard the washer. 3. To install, reverse the removal procedure. - Install a new hydraulic timing chain tensioner washer. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Install the Front Cover Aligner and tighten the 5 bolts and 5 stud bolts. Tighten to............................. .............................................................................................................................................................. .........19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2063 Timing Cover: Service and Repair Engine Front Cover Lower End Components Accessory Drive Brackets Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2064 Engine Front Cover Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2065 Removal 1. Disconnect the battery ground cable. 2. Drain the cooling system. 3. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal See: Seals and Gaskets/Front Crankshaft Seal/Service and Repair. 4. Remove the nut and detach the wiring harness bracket from the front cover. 5. Remove the 5 oil pan-to-front cover bolts. 6. Disconnect the lower radiator hose. 7. Remove the bolt and the drive belt tensioner. 8. Disconnect the heater hose from the coolant pump. 9. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 10. Remove the nut and disconnect the generator B+ terminal. 11. Disconnect the generator electrical connector and detach the wiring harness retainer. 12. Remove the 3 generator bracket bolts and the generator bracket. 13. Remove the coil bracket-to-A/C compressor and power steering pump bracket bolt. 14. Remove the 4 bolts and the A/C compressor and power steering pump bracket. 15. Remove and discard the CKP sensor wiring harness retainers. 16. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 17. Disconnect the upper radiator hose from the thermostat housing. 18. Disconnect the heater hose from the thermostat housing. 19. NOTE: The bypass hose will be removed with the thermostat housing. Release the bypass hose clamp from the coolant pump end. 20. Remove the 3 bolts and the thermostat housing. 21. NOTE: Note the positions of the stud bolts for installation reference. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2066 Remove the 10 bolts, the engine front cover and the gasket. Discard the gasket. Installation 1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of the old front cover gasket and the silicone sealer. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic scraping tool. Follow the directions on the packaging. 2. Position the front cover gasket. NOTICE: If 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. 3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces. 4. Apply silicone gasket and sealant to the front cover in 2 places as shown. 5. NOTE: Make sure the stud bolts are installed in their original positions. Position the engine front cover and install the 10 bolts. - Tighten to 19 Nm (168 lb-in). 6. NOTE: Make sure the coolant bypass hose is attached to the coolant pump. Position the thermostat housing and install the 3 bolts. - Tighten to 11 Nm (97 lb-in). 7. Position the bypass hose clamp. 8. Connect the upper radiator hose to the thermostat housing. 9. Connect the heater hose to the thermostat housing. 10. Connect the ECT sensor electrical connector. 11. Install new wiring harness retainers and position the CKP sensor wiring. 12. Connect the CKP sensor electrical connector. 13. Position the A/C compressor and power steering pump bracket and install the 4 bolts. - Tighten to 42 Nm (31 lb-ft). 14. Install the ignition coil bracket-to-A/C compressor and power steering pump bracket bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2067 - Tighten to 10 Nm (89 lb-in). 15. Position the generator bracket and install the 3 bolts. - Tighten to 42 Nm (31 lb-ft). 16. Connect the generator electrical connector and attach the wiring harness retainer. 17. Connect the generator B+ terminal and install the nut. - Tighten to 8 Nm (71 lb-in). 18. Connect the heater hose to the coolant pump. 19. Position the accessory drive belt tensioner and install the bolt. - Tighten to 47 Nm (35 lb-ft). 20. Connect the lower radiator hose. 21. Install the 5 cylinder block cradle-to-front cover bolts. - Tighten to 14 Nm (124 lb-in). 22. Position the wiring harness bracket and install the nut. - Tighten to 20 Nm (177 lb-in). 23. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal See: Seals and Gaskets/Front Crankshaft Seal/Service and Repair. 24. Connect the battery ground cable. 25. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are four 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 four 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. The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection section. For additional information, refer to the Engine System - General Information. Verification of incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General Information. Variable Camshaft Timing (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 indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), engine coolant temperature (ECT), engine oil temperature (EOT), CMP, throttle position (TP), mass air flow (MAF), and CKP sensors 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 2072 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. 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 two 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. VCT System Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Cover / Housing > Component Information > Service and Repair Variable Valve Timing Cover / Housing: Service and Repair Variable Camshaft Timing (VCT) Housing Cleaning and Inspection 1. Remove the screw and the Variable Camshaft Timing (VCT) oil control solenoid. - To install, tighten to 5 Nm (44 lb-in). 2. Clean the mating surfaces and oil passages with metal surface prep. Follow the directions on the packaging. 3. Inspect the VCT housing for pitting, cracks or damaged sealing surfaces. Install a new VCT housing if damaged. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1 > Page 2080 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 > Page 2083 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams > Page 2084 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 Variable Camshaft Timing (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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... ............................................207-276 kPa (30-40 psi) Engine running.................................................. .................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2089 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to Spring Lock Couplings See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Spring Lock Couplings. 4. NOTE: 4.6L shown, 4.0L similar. Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail. 5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 6. Connect the battery ground cable. 7. 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. 8. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 9. NOTE: 4.6L shown, 4.0L similar. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2090 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values Hot Idle ............................................................................................................ .......................................................................................... 750 - 820 RPM Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Intake Air System Components Exploded View Air Filter Element: Service and Repair Intake Air System Components - Exploded View Intake Air System Components - Exploded View Coolant Expansion Tank Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Intake Air System Components Exploded View > Page 2099 Intake Air System Components - 4.6L (3V) 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Intake Air System Components Exploded View > Page 2100 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element 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 (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL element. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious 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. NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Base ignition timing................................................................................................................10 degrees Before Top Dead Center (BTDC), Non-adjustable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Spark Plug Wires Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Powertrain Management/Ignition System/Description and Operation in the Description and Operation. Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ...............................................................Specification Spark Plug Gap.................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2118 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................17 Nm (150 lb-in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2119 Spark Plug: Application and ID Item....................................................................................................................................................... ...............................................................Specification Spark Plug type.................................................................................................................................... ....................................................................AGSF24N Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2120 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. - Install a new 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. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2121 6. Inspect for overheating, identified by white or light gray spots and a 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. - Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 2124 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Powertrain Management/Ignition System/Description and Operation in the Description and Operation. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs. Remove the spark plugs. - To install, tighten to 17 Nm (150 lb-in). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2128 Compression Check: Testing and Inspection Engine 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 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2129 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 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 within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Install a new gasket, the coolant pump and the 13 bolts. Tighten to.................................................... ..................................................................................................................................................10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2133 Water Pump: Service and Repair Coolant Pump - 4.0L SOHC Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Cooling System/Service and Repair/Procedures/Cooling System Draining, Filling and Bleeding. 2. Remove the cooling fan. For additional information, refer to Cooling Fan See: Cooling System/Radiator Cooling Fan/Fan Blade/Service and Repair. 3. Remove the accessory drive belt. 4. Remove the bolts and the coolant pump pulley. - To install, tighten to 25 Nm (18 lb-ft). 5. Release the clamp and disconnect the coolant pump bypass hose. 6. Release the clamp and disconnect the heater hose. 7. Release the clamp and disconnect the lower radiator hose. 8. Remove the bolts, the coolant pump and the gasket. - To install, tighten to 10 Nm (89 lb-in). 9. NOTICE: 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 gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2134 Clean the mating surfaces with a plastic scraper and metal surface prep. Follow the directions on the packaging. 10. To install, reverse the removal procedure. - Install a new coolant pump gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. .............................................. 12.2 quarts (11.5 liters) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2140 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 (V6-4.0L (2009)) 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 Accessory Drive Belt Generator Coolant Crossover Manifold Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2144 Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Procedures/Cooling System Draining, Filling and Bleeding. 2. Remove the intake manifold. 3. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator pulley. 4. Disconnect the electrical connector. 5. Loosen the generator nuts. - To install, tighten to 25 Nm (18 lb-ft). 6. 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 lb-in). 7. Disconnect the PCV heater hose from the coolant crossover manifold assembly. 8. Disconnect the heater hose from the coolant crossover manifold assembly. 9. Disconnect the upper radiator hose from the coolant crossover manifold assembly. 10. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets. - To install, tighten to 10 Nm (89 lb-in). 11. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Page 2145 - Install new gaskets. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir Coolant Reservoir: Customer Interest Cooling System - Coolant Leaks From The Reservoir TSB 09-11-12 06/15/09 COOLANT EXPANSION TANK LEAKS - 4.0L ENGINE FORD: 2006-2009 Explorer 2007-2009 Explorer Sport Trac MERCURY: 2006-2009 Mountaineer ISSUE Some 2006-2009 Explorer, Mountaineer and 2007-2009 Explorer Sport Trac vehicles equipped with 4.0L engine may experience coolant leaking from the coolant expansion tank. This may be due to cracks that develop in the coolant expansion tank at the radiator mounting bolt locations. ACTION Replace the coolant expansion tank. Follow the service procedure steps to correct the condition. SERVICE PROCEDURE 1. Allow the engine to cool before removing the coolant expansion tank. 2. Disconnect the coolant overflow hose. 3. Remove the bolts and the coolant expansion tank. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir > Page 2154 4. Make sure the J clips in the upper radiator mounting boss sit flush. (Figure 2) 5. Install the updated coolant expansion tank. 6. Use the new bolt fasteners. 7. Torque to 43 lb-in (4.8 N.m). 8. Connect the coolant overflow hose. 9. Verify proper coolant level. 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 091112A 2006-2009 Explorer, 0.4 Hr. Mountaineer, 2007-2009 Explorer Sport Trac: Replace Coolant Expansion Tank(Do Not Use With 8080A) DEALER CODING CONDITION BASIC PART NO. CODE 8A080 01 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir Coolant Reservoir: All Technical Service Bulletins Cooling System - Coolant Leaks From The Reservoir TSB 09-11-12 06/15/09 COOLANT EXPANSION TANK LEAKS - 4.0L ENGINE FORD: 2006-2009 Explorer 2007-2009 Explorer Sport Trac MERCURY: 2006-2009 Mountaineer ISSUE Some 2006-2009 Explorer, Mountaineer and 2007-2009 Explorer Sport Trac vehicles equipped with 4.0L engine may experience coolant leaking from the coolant expansion tank. This may be due to cracks that develop in the coolant expansion tank at the radiator mounting bolt locations. ACTION Replace the coolant expansion tank. Follow the service procedure steps to correct the condition. SERVICE PROCEDURE 1. Allow the engine to cool before removing the coolant expansion tank. 2. Disconnect the coolant overflow hose. 3. Remove the bolts and the coolant expansion tank. (Figure 1) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Reservoir: > 09-11-12 > Jun > 09 > Cooling System - Coolant Leaks From The Reservoir > Page 2160 4. Make sure the J clips in the upper radiator mounting boss sit flush. (Figure 2) 5. Install the updated coolant expansion tank. 6. Use the new bolt fasteners. 7. Torque to 43 lb-in (4.8 N.m). 8. Connect the coolant overflow hose. 9. Verify proper coolant level. 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 091112A 2006-2009 Explorer, 0.4 Hr. Mountaineer, 2007-2009 Explorer Sport Trac: Replace Coolant Expansion Tank(Do Not Use With 8080A) DEALER CODING CONDITION BASIC PART NO. CODE 8A080 01 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Technical Service Bulletins > Page 2161 Coolant Reservoir: Service and Repair Coolant Expansion Tank NOTICE: 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 lb-in). 4. To install, reverse the removal procedure. - Fill the coolant expansion tank with a 50/50 mixture of coolant and clean, drinkable water. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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): 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). FCV Duty Cycle Output From PCM (Negative Duty Cycle) For relay controlled fans: The PCM controls the fan operation through the fan control (FC), (single speed fan applications), low fan control (LFC), medium fan control (MFC), and 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 cooling fan speed is controlled by a combination of these outputs. Refer to the following table. 2.0L Focus (with A/C): PCM FC Output State For Cooling Fan Speeds 2.5L Escape: PCM FC Output State For Cooling Fan Speeds Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Fan Speed Sensor (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 PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. For additional information on the cooling fan clutch, refer to the Cooling Fan Clutch. Cooling Fan Clutch with Fan Speed Sensor (FSS) Cooling Fan Clutch with FSS Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation Vehicle equipped with a 4.6L (3V) 1. Remove the Air Cleaner (ACL) outlet pipe. All vehicles 2. Remove the coolant expansion tank. For additional information, refer to Coolant Expansion Tank See: Coolant Reservoir/Service and Repair. 3. Remove the bolt and position the power steering fluid reservoir aside. - To install, tighten to 10 Nm (89 lb-in). 4. Remove the 2 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 lb-in). 5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket bolt. - To install, tighten to 7 Nm (62 lb-in). 7. NOTICE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan. - To install, tighten to 55 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Service and Repair > Page 2172 8. Remove the 4 bolts and separate the fan from the fan clutch. - To install, tighten to 7 Nm (62 lb-in). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2176 Fan Clutch: Description and Operation Engine Control Components Cooling Fan Clutch The cooling fan clutch is an electrically actuated viscous clutch that consists of three 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. Cooling Fan Clutch with Fan Speed Sensor (FSS) Cooling Fan Clutch with Fan Speed Sensor (FSS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Diagrams > Page 2177 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2182 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2183 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Control Components Engine Coolant Temperature (ECT) Sensor The ECT 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 ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Typical Thread Type Sensor Typical Thread Type ECT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2184 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC Removal and Installation 1. Drain the cooling system. 2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2188 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 2189 Engine Temperature Sensor: Description and Operation Engine Control Components Cylinder Head Temperature (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. For additional information, refer to Powertrain Control Software See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Cooling Fan Shroud Removal and Installation Vehicles equipped with a 4.6L (3V) engine 1. Remove the Air Cleaner (ACL) outlet pipe. All vehicles 2. Remove the coolant expansion tank. For additional information, refer to Coolant Expansion Tank See: Coolant Reservoir/Service and Repair. 3. Remove the bolt and position the power steering fluid reservoir aside. - To install, tighten to 10 Nm (89 lb-in). 4. Remove the 2 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 lb-in). 5. Disconnect the fan clutch electrical connector. 6. Remove the fan clutch wiring harness bracket bolt. - To install, tighten to 7 Nm (62 lb-in). 7. NOTICE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan. - To install, tighten to 55 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2193 8. Remove the 2 bolts and the lower fan shroud. - To install, tighten to 7 Nm (62 lb-in). 9. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core Heater Core: Testing and Inspection Heater Core Climate Control System Component Tests Heater Core 1. NOTE: If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: See: Heater Core - Plugged Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 2201 Heater Core: Testing and Inspection Heater Core - Plugged Climate Control System Component Tests Heater Core - Plugged 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, using a suitable temperature measuring device, check the heater core inlet and outlet hose to see if they are hot. If the inlet hose is not hot: - the heater control valve may be stuck closed. - the thermostat is not working correctly. If the outlet hose is not hot: - the heater core may have an air pocket. - the heater core may be restricted or plugged. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 2202 Heater Core: Testing and Inspection Heater Core - Pressure Test Climate Control System Component Tests Heater Core - Pressure Test Use the Pressure Test Kit to perform the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the Pressure Test Kit in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. See: Heater Core - Bench Test Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 2203 Heater Core: Testing and Inspection Heater Core - Bench Test Climate Control System Component Tests Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester from the Pressure Test Kit to the adapter. 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. For additional information, refer to Heater Core And Evaporator Core Housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/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. 8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2206 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2207 Heater Core: Service and Repair Auxiliary Heater Core Auxiliary Heater Core Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2208 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. 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 heater core and evaporator core housing bolts and auxiliary heater core and evaporator core 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core > Page 2209 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair Radiator: Service and Repair Radiator Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Procedures/Cooling System Draining, Filling and Bleeding. Vehicles equipped with a 4.6L (3V) engine 3. Remove the Air Cleaner (ACL) outlet pipe. All vehicles 4. Remove the coolant expansion tank. For additional information, refer to Coolant Expansion Tank See: Coolant Reservoir/Service and Repair. 5. Remove the bolt and position the power steering fluid reservoir aside. - To install, tighten to 10 Nm (89 lb-in). 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 and position the air deflector aside. 11. Remove the 2 latch assemblies from the transmission cooler tubes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2213 12. Using the Transmission Cooler Line Disconnect Tool, disconnect the 2 transmission cooler tubes. 13. Remove the 2 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 lb-in). 14. Disconnect the fan clutch electrical connector. 15. Remove the fan clutch wiring harness bracket bolt. - To install, tighten to 7 Nm (62 lb-in). 16. NOTICE: Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged. NOTE: 4.6L (3V) engine shown, 4.0L SOHC engine similar. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan. - To install, tighten to 55 Nm (41 lb-ft). 17. Remove the 2 bolts and the lower fan shroud. 18. Detach the A/C tube from the retainer on the radiator support bracket. 19. NOTE: LH shown RH similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2214 Remove the 2 radiator support bracket-to-radiator support bolts. - To install, tighten to 15 Nm (133 lb-in). 20. Lift the radiator and A/C condenser assembly off the frame supports and move the assembly toward the front of the engine. 21. Remove the radiator top seal. 22. NOTE: Do not remove the A/C condenser seals. NOTE: LH shown RH similar. Deflect the A/C condenser seals and remove the 2 A/C condenser-to-radiator support bracket bolts. - To install, tighten to 12 Nm (106 lb-in). 23. Lift the A/C condenser off the supports and move the A/C condenser toward the front of the vehicle. 24. Remove the radiator and the radiator support brackets as an assembly. - Move the LH radiator support bracket past the ABS module before removing the radiator from the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Page 2215 25. Remove the 4 bolts and separate the 2 radiator support brackets and the radiator. - To install, tighten to 12 Nm (106 lb-in). 26. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Fan Speed Sensor (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 PCM uses the frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan clutch. For additional information on the cooling fan clutch, refer to the Cooling Fan Clutch. Cooling Fan Clutch with Fan Speed Sensor (FSS) Cooling Fan Clutch with FSS Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2224 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2225 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Control Components Engine Coolant Temperature (ECT) Sensor The ECT 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 ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Typical Thread Type Sensor Typical Thread Type ECT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2226 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC Removal and Installation 1. Drain the cooling system. 2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 2230 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2231 Engine Temperature Sensor: Description and Operation Engine Control Components Cylinder Head Temperature (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. For additional information, refer to Powertrain Control Software See: Powertrain Management/Computers and Control Systems/Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Opening Temperature Starts to open....................................................................................................................................... ...................................................90-94°C (194-201°F) Fully open....................................................... ...................................................................................................................................................106°C (223°F) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat and Thermostat Housing - Exploded View Thermostat: Service and Repair Thermostat and Thermostat Housing - Exploded View Thermostat and Thermostat Housing - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Thermostat and Thermostat Housing - Exploded View > Page 2237 Thermostat: Service and Repair Thermostat Thermostat - 4.0L SOHC Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Procedures/Cooling System Draining, Filling and Bleeding. 2. Release the clamp and disconnect the upper radiator hose from the thermostat housing cover. 3. Remove the bolts and the thermostat housing cover. - To install, tighten to 10 Nm (89 lb-in). 4. Remove the thermostat. 5. NOTE: Inspect the thermostat housing cover O-ring seal. Install a new O-ring seal if necessary. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Install a new gasket, the coolant pump and the 13 bolts. Tighten to.................................................... ..................................................................................................................................................10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2241 Water Pump: Service and Repair Coolant Pump - 4.0L SOHC Removal and Installation 1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding See: Service and Repair/Procedures/Cooling System Draining, Filling and Bleeding. 2. Remove the cooling fan. For additional information, refer to Cooling Fan See: Radiator Cooling Fan/Fan Blade/Service and Repair. 3. Remove the accessory drive belt. 4. Remove the bolts and the coolant pump pulley. - To install, tighten to 25 Nm (18 lb-ft). 5. Release the clamp and disconnect the coolant pump bypass hose. 6. Release the clamp and disconnect the heater hose. 7. Release the clamp and disconnect the lower radiator hose. 8. Remove the bolts, the coolant pump and the gasket. - To install, tighten to 10 Nm (89 lb-in). 9. NOTICE: 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 gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2242 Clean the mating surfaces with a plastic scraper and metal surface prep. Follow the directions on the packaging. 10. To install, reverse the removal procedure. - Install a new coolant pump gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 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 (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 powertrain control module (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/Catalyst Efficiency Monitor. For most vehicles, only two 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 (PZEVs) use three HO2Ss. The stream 1 sensor (HO2S11) located before the catalyst is used for primary fuel control, the stream 2 sensor (HO2S12) is used to monitor the light-off catalyst, and the stream 3 sensor (HO2S13) located after the catalyst is used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). V-Engines V-Engines In-Line Engines In-Line Engines Catalytic Converter 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 three way catalytic converter (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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2247 catalyst. Three Way Catalytic Converter (TWC) Conversion Efficiency A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window 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. TWC Conversion Efficiency Chart TWC Conversion Efficiency Chart Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. 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 three HO2Ss 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. Typical Bank 1 Catalyst 2 H2OS Configuration Typical Bank 1 Catalyst 2 HO2S Configuration Typical Bank 1 Catalyst 3 H2OS Configuration Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2248 Typical Bank 1 Catalyst 3 HO2S Configuration Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to the Exhaust System for the exhaust system exploded view. Three Way Catalytic (TWC) Converter The TWC contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC 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 PCM with information related to the oxygen content of the exhaust gas. For additional information on the HO2S, refer to Engine Control Components See: Powertrain Management/Computers and Control Systems/Description and Operation/Engine Control Components. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2249 Catalytic Converter: Service and Repair Exhaust System - Exploded View 4.0L Explorer Sport Trac NOTE: Vehicle body removed for clarity. 4.6L Explorer Sport Trac NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2250 4.0L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2251 4.6L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2252 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Install 6 new RH exhaust manifold studs. Tighten to............................................................................ ........................................................................................................................12 Nm (106 lb-in). Install a new gasket, the RH exhaust manifold and the 6 new nuts. Tighten to................................... .............................................................................................................................................................. ......22 Nm (16 lb-ft). Install 6 new LH exhaust manifold studs. Tighten to............................................................................ ........................................................................................................................12 Nm (106 lb-in). Install a new gasket, the LH exhaust manifold and the 6 new nuts. Tighten to.................................... .............................................................................................................................................................. ......22 Nm (16 lb-ft) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures Exhaust Manifold Cleaning and Inspection 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. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On(R) GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end. Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2258 Exhaust Manifold: Removal and Replacement Exhaust Manifold - LH Exhaust Manifold - LH Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter Y-pipe aside. - Discard the nuts. 3. Remove the 6 nuts, the LH exhaust manifold and the gasket. - Discard the nuts and the gasket. 4. Remove and discard the 6 LH exhaust manifold studs. Installation 1. Inspect the LH exhaust manifold gasket surfaces for flatness. 2. Install 6 new LH exhaust manifold studs. - Tighten to 12 Nm (106 lb-in). 3. Position a new gasket, the LH exhaust manifold and install 6 new nuts. - Tighten to 22 Nm (16 lb-ft). 4. Position the dual converter Y-pipe and install 4 new nuts. - Tighten to 40 Nm (30 lb-ft). Exhaust Manifold - RH Exhaust Manifold - RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2259 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the EGR tube. 3. Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts and position the dual converter Y-pipe aside. - Discard the nuts. 4. Remove the 6 nuts, the RH exhaust manifold and the gasket. - Discard the nuts and the gasket. 5. Remove and discard the 6 RH exhaust manifold studs. Installation 1. Inspect the RH exhaust manifold gasket surfaces for flatness. 2. Install 6 new RH exhaust manifold studs. - Tighten to 12 Nm (106 lb-in). 3. Position a new gasket, the RH exhaust manifold and install 6 new nuts. - Tighten to 22 Nm (16 lb-ft). 4. Position the dual converter Y-pipe and install 4 new nuts. - Tighten to 40 Nm (30 lb-ft). 5. Install the EGR tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View Exhaust Pipe: Service and Repair Exhaust System - Exploded View Exhaust System - Exploded View 4.0L Explorer Sport Trac NOTE: Vehicle body removed for clarity. 4.6L Explorer Sport Trac NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2264 4.0L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2265 4.6L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2266 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2267 Exhaust Pipe: Service and Repair Exhaust Y-Pipe - Dual Catalytic Converter Exhaust Y-Pipe - Dual Catalytic Converter Removal NOTICE: 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. 2. Using a suitable jack, support the exhaust system. 3. Disconnect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) electrical connectors. 4. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, 2 nuts and gasket. - Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly 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: RH side shown, LH similar. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. NOTE: Do not fully tighten the exhaust Y-pipe dual catalytic converter-to-exhaust manifold joint. Position the exhaust Y-pipe dual catalytic converter to the exhaust manifold and loosely tighten all 4 new nuts to stiffen the joint enough to maintain position. - Tighten to 8 Nm (71 lb-in) and then add additional torque if needed to stiffen the joint. 2. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts. Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, 2 bolts and 2 new nuts. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2268 - Tighten to 40 Nm (30 lb-ft). 3. NOTE: RH shown, LH similar. Tighten the 4 new exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts. - Tighten to 40 Nm (30 lb-ft). 4. Install the transmission support crossmember. 5. Connect the HO2S and CMS electrical connectors. 6. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. For additional information, refer the Exhaust System Alignment See: Service and Repair/Exhaust System Alignment. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2269 Exhaust Pipe: Service and Repair Tailpipe Tailpipe Removal NOTICE: 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. 2. Loosen the muffler assembly-to-tail pipe Torca(R) clamp. 3. Disconnect the rubber isolator and remove the tail pipe. Installation 1. Position the tail pipe and connect the rubber isolator. 2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tail pipe surface area of any rust. Position the muffler assembly-to-tail pipe and make sure the tab on the muffler assembly is seated inside the notch on the tail pipe and then tighten the Torca(R) clamp. - Tighten to 48 Nm (35 lb-ft). 3. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. For additional information, refer the Exhaust System Alignment See: Service and Repair/Exhaust System Alignment. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View Muffler: Service and Repair Exhaust System - Exploded View Exhaust System - Exploded View 4.0L Explorer Sport Trac NOTE: Vehicle body removed for clarity. 4.6L Explorer Sport Trac NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2274 4.0L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2275 4.6L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2276 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2277 Muffler: Service and Repair Muffler Muffler Removal All vehicles NOTICE: 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. 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, the muffler inlet pipe must be cut. 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. 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, the muffler inlet pipe must be cut. 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. All vehicles 5. Loosen the muffler assembly-to-tail pipe Torca(R) clamp. 6. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts, 2 nuts and gasket. - Discard the exhaust Y-pipe dual catalytic converter-to-muffler assembly nuts and gasket. 7. Disconnect the rubber isolators and remove the muffler assembly. Installation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2278 All vehicles 1. Position the muffler assembly and connect the rubber isolators. 2. NOTE: Using an abrasive pad, clean the muffler assembly-to-tail pipe surface area of any rust. Position the muffler assembly-to-tail pipe and make sure the tab on the muffler assembly is seated inside the notch on the tail pipe and then tighten the Torca(R) clamp. - Tighten to 48 Nm (35 lb-ft). 4.0L Explorer Sport Trac 3. 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. 4. 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 not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. Tighten to 47 Nm (35 lb-ft). 4.6L Explorer Sport Trac 5. 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. 6. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust System - Exploded View > Page 2279 If not welded to the muffler inlet pipe, make sure that the service exhaust coupler is against the alignment nub and is positioned approximately at the 2 o'clock position facing the muffler. If the muffler inlet pipe does not have an alignment nub, center the exhaust coupler over the muffler inlet pipe joint and position it at approximately the 2 o'clock position facing the muffler. Tighten to 47 Nm (35 lb-ft). All Vehicles 7. NOTE: Install new exhaust Y-pipe dual catalytic converter-to-muffler assembly gasket and nuts. Install the exhaust Y-pipe-dual catalytic converter-to-muffler assembly new gasket, 2 bolts and 2 new nuts. - Tighten to 40 Nm (30 lb-ft). 8. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at zero load, then carry out the exhaust system alignment procedure. For additional information, refer the Exhaust System Alignment See: Service and Repair/Exhaust System Alignment. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. 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), which delivers 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 torque-based 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 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: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2 wires). - There are two designs: parallel and in-line. 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-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - 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. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP 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). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. For additional information on the APP sensor, refer to Engine Control Components See: Computers and Control Systems/Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy 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) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2286 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 two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring 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, appropriate corrective action is taken. ETC System With A 3-Track APP Sensor Failure Mode And Effects Management: a - ETC illuminates or displays a message on the message center immediately; MIL illuminates after 2 driving cycles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2287 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management: Electronic Throttle Monitor Operation: a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. APP and TP Sensor Inputs Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2288 Accelerator Pedal Position (APP) Sensor Check: Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Throttle Position (TP) Sensor Check: a - Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check: a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2297 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2298 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 2304 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 2305 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2306 Engine Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2307 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2308 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2309 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2310 Engine Control Module: Diagrams C175B Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2311 C175B Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2312 C175E Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2313 C175E Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2314 C175E Part 3 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2315 C175T Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2316 C175T Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Description The EEPROM is contained in an integrated circuit 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 DTC 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. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. 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. Neutral Profile Correction In order for the misfire detection system to function properly, any mechanical inaccuracies in the crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is reset. Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should also be relearned any time the CKP sensor is replaced or major engine repairs have been completed. To determine if the neutral profile learning has been completed, check the MP_LRN parameter identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any misfire DTCs. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer 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 be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old PCM 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 programmed PCM 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Procedures > Page 2319 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 (V6-4.0L (2009)) 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 > Procedures > Page 2320 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) A/C Tube Brackets PCM Removal All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Procedures > Page 2321 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning Vehicles equipped with a 4.6L (3V) engine 2. Remove the Air Cleaner (ACL). All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the 2 bolts and the PCM. Installation All vehicles 1. Install the PCM and the 2 bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). 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 ACL. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft System (PATS) Parameter Reset Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2325 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2326 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 2331 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Fuel Pump Driver Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Fuel Pump Driver Module > Page 2337 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 2338 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 2339 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) - Explorer Sport Trac Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector. 3. Remove the 2 bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2343 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2344 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2348 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2349 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2355 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2356 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2360 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2361 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2362 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2363 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2364 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 2369 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 2370 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2373 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2374 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2375 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2376 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > 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 Engine Control Components 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. Typical Clutch Pedal Position (CPP) Switch Typical Clutch Pedal Position (CPP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2383 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2384 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Control Components Engine Coolant Temperature (ECT) Sensor The ECT 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 ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Typical Thread Type Sensor Typical Thread Type ECT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2385 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC Removal and Installation 1. Drain the cooling system. 2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2389 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2390 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2391 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2392 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2393 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2397 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2398 Engine Temperature Sensor: Description and Operation Engine Control Components Cylinder Head Temperature (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. For additional information, refer to Powertrain Control Software See: Computers and Control Systems/Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2404 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2405 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2406 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2407 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Fuel Pump (FP). For additional information, refer to Fuel Pump See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2408 Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the FP body. 2. Route the fuel level sender wire through the center of the FP. 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the FP and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2409 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the FP. For additional information, refer to Fuel Pump See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2413 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2414 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2415 Fuel Tank Pressure Sensor: Description and Operation Engine Control Components Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2416 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Removal and Installation WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Evaporative Emission (EVAP) canister. For additional information, refer to Evaporative Emission Canister See: Emission Control Systems/Evaporative Emissions System/Evaporative Emission Control Canister/Service and Repair. 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel Pump (FP) module and the vapor vent valves. 5. Remove the FTP sensor and vapor tube assembly. 6. To install, reverse the removal procedure. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2420 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2421 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2422 Intake Air Temperature Sensor: Description and Operation Engine Control Components Intake Air Temperature (IAT) 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 sensor 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. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two 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 two IAT sensors. Both sensors are thermistor type devices and operate as described above. 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. Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors 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 Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type MAF sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2426 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2427 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2428 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2429 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > 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 Engine Control Components 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. Typical Manifold Absolute Pressure (MAP) Sensor Typical Manifold Absolute Pressure (MAP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Control Components Engine Oil Temperature (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. Typical Thread Type Sensor Typical EOT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2440 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2441 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2442 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2443 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2444 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2445 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2446 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2447 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2448 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2451 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2452 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2453 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Engine Control Components 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. Typical Heated Oxygen Sensor (HO2S) Typical Heated Oxygen Sensor (HO2S) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) > Page 2456 Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S) Engine Control Components Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View > Page 2459 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the HO2S electrical connector. 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. Installation 1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the HO2S electrical connector. 4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View > Page 2460 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the CMS electrical connector. 4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. Installation 1. Apply a light coat of anti-seize lubricant to the threads of the CMS. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the CMS electrical connector. 4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2464 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 EPC pressure during increased engine load, for example during parking maneuvers. Typical Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2467 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Engine Control Components 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 EPC pressure during increased engine load, for example, during parking maneuvers. Typical Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 2473 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2477 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2478 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor > Page 2481 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2482 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2483 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2484 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2488 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2489 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2490 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2491 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2492 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2493 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2494 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2495 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Locations > Page 2496 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) 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 2501 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) Engine Control Components 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 speed, 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. Typical Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 2508 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2513 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2514 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2518 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2519 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2520 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2521 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2522 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) 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 Pressure Sensor/Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2526 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2527 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2528 Fuel Pressure Sensor/Switch: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2529 Fuel Pressure Sensor/Switch: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 2530 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2534 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2535 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2536 Fuel Temperature Sensor: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2537 Fuel Temperature Sensor: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2538 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2542 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2543 Inertia Fuel Shutoff Switch: Description and Operation Engine Control Components Inertia Fuel Shut-off (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone 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, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2544 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. NOTE: 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 2 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2548 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2549 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor > Page 2552 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2553 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2554 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2555 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2561 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2562 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2565 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2566 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2567 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2568 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2572 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2573 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2574 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2575 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2576 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Lock Cylinder - Functional 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. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys must be programmed. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 2582 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Lock Cylinder - Non Functional Removal 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. 3. Program the new PATS keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2586 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2587 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2588 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2589 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... ............................................207-276 kPa (30-40 psi) Engine running.................................................. .................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2594 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to Spring Lock Couplings See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Spring Lock Couplings. 4. NOTE: 4.6L shown, 4.0L similar. Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail. 5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 6. Connect the battery ground cable. 7. 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. 8. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 9. NOTE: 4.6L shown, 4.0L similar. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2595 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values Hot Idle ............................................................................................................ .......................................................................................... 750 - 820 RPM Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View Air Filter Element: Service and Repair Intake Air System Components - Exploded View Intake Air System Components - Exploded View Coolant Expansion Tank Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 2604 Intake Air System Components - 4.6L (3V) 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 2605 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element 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 (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL element. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious 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. NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Base ignition timing................................................................................................................10 degrees Before Top Dead Center (BTDC), Non-adjustable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Spark Plug Wires Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Ignition System/Description and Operation in the Description and Operation. Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ...............................................................Specification Spark Plug Gap.................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 2623 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................17 Nm (150 lb-in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2624 Spark Plug: Application and ID Item....................................................................................................................................................... ...............................................................Specification Spark Plug type.................................................................................................................................... ....................................................................AGSF24N Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2625 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. - Install a new 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. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2626 6. Inspect for overheating, identified by white or light gray spots and a 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. - Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 2629 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Ignition System/Description and Operation in the Description and Operation. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs. Remove the spark plugs. - To install, tighten to 17 Nm (150 lb-in). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test - Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2633 Compression Check: Testing and Inspection Engine 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 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 If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2634 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 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 within 75% of the highest reading. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2639 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2640 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2644 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2645 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2646 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2647 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2648 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2652 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2653 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2654 Intake Air Temperature Sensor: Description and Operation Engine Control Components Intake Air Temperature (IAT) 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 sensor 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. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two 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 two IAT sensors. Both sensors are thermistor type devices and operate as described above. 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. Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors 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 Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type MAF sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations Brake Signal: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2658 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Locations > Page 2659 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 2662 Brake Signal: Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2667 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 2668 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2671 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 2672 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2673 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 2674 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation Clutch Switch: Description and Operation Engine Control Components 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. Typical Clutch Pedal Position (CPP) Switch Typical Clutch Pedal Position (CPP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2681 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2682 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Control Components Engine Coolant Temperature (ECT) Sensor The ECT 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 ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Typical Thread Type Sensor Typical Thread Type ECT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2683 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC Removal and Installation 1. Drain the cooling system. 2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2687 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2688 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2689 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2690 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2691 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2695 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations Electronic Throttle Actuator: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2699 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2700 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Locations > Page 2701 Electronic Throttle Actuator: Description and Operation Engine Control Components Electronic Throttle Actuator Control (TAC) The electronic TAC is a DC motor controlled by the PCM (requires 2 wires). There are 2 designs for the TAC, parallel and in-line. 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-line design has a separate motor housing. An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. Typical In-line TAC Design Typical In-line TAC Design Typical Parallel TAC Design Typical Parallel TAC Design Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. 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), which delivers 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 torque-based 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 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: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2 wires). - There are two designs: parallel and in-line. 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-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - 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. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP 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). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. For additional information on the APP sensor, refer to Engine Control Components See: Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy 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) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2705 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 two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring 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, appropriate corrective action is taken. ETC System With A 3-Track APP Sensor Failure Mode And Effects Management: a - ETC illuminates or displays a message on the message center immediately; MIL illuminates after 2 driving cycles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2706 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management: Electronic Throttle Monitor Operation: a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. APP and TP Sensor Inputs Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page 2707 Accelerator Pedal Position (APP) Sensor Check: Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Throttle Position (TP) Sensor Check: a - Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check: a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2716 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2717 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2723 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2724 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2725 Engine Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2726 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2727 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2728 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2729 Engine Control Module: Diagrams C175B Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2730 C175B Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2731 C175E Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2732 C175E Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2733 C175E Part 3 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2734 C175T Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2735 C175T Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Description The EEPROM is contained in an integrated circuit 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 DTC 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. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. 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. Neutral Profile Correction In order for the misfire detection system to function properly, any mechanical inaccuracies in the crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is reset. Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should also be relearned any time the CKP sensor is replaced or major engine repairs have been completed. To determine if the neutral profile learning has been completed, check the MP_LRN parameter identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any misfire DTCs. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer 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 be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old PCM 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 programmed PCM 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2738 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2739 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) A/C Tube Brackets PCM Removal All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2740 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning Vehicles equipped with a 4.6L (3V) engine 2. Remove the Air Cleaner (ACL). All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the 2 bolts and the PCM. Installation All vehicles 1. Install the PCM and the 2 bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). 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 ACL. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning 6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft System (PATS) Parameter Reset Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2744 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2745 Engine Temperature Sensor: Description and Operation Engine Control Components Cylinder Head Temperature (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. For additional information, refer to Powertrain Control Software See: Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2751 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2752 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2753 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2754 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Fuel Pump (FP). For additional information, refer to Fuel Pump See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2755 Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the FP body. 2. Route the fuel level sender wire through the center of the FP. 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the FP and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2756 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the FP. For additional information, refer to Fuel Pump See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2760 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2761 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2762 Fuel Tank Pressure Sensor: Description and Operation Engine Control Components Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2763 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Removal and Installation WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Evaporative Emission (EVAP) canister. For additional information, refer to Evaporative Emission Canister See: Emission Control Systems/Evaporative Emissions System/Evaporative Emission Control Canister/Service and Repair. 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel Pump (FP) module and the vapor vent valves. 5. Remove the FTP sensor and vapor tube assembly. 6. To install, reverse the removal procedure. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2771 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2772 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2773 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2774 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2775 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2776 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2777 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2778 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2779 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2780 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2782 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2783 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2784 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2785 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2786 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2787 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2788 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2789 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2790 14-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2791 Information Bus: Description and Operation Communications Network NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). Vehicle communication utilizes both Medium Speed (MS) and High Speed (HS) 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 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 Controller Area Network (MS-CAN) - High Speed Controller Area Network (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 Control Module (ACM). Network Topology Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2792 Medium Speed Controller Area Network (MS-CAN) Operation The MS-CAN 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: - Accessory Protocol Interface Module (APIM) - Audio Control Module (ACM) - Driver Seat Module (DSM) (if equipped) - HVAC module (if equipped) - Instrument Cluster (IC) - Parking Aid Module (PAM) (if equipped) - Power Running Board (PRB) module (if equipped) - Rear Entertainment Module (RETM) (if equipped) - Satellite Digital Audio Receiver System (SDARS) module (if equipped) - Smart Junction Box (SJB) High Speed Controller Area Network (HS-CAN) Operation The HS-CAN communicates using bussed messages. The HS-CAN 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: - 4X4 control module (if equipped) - ABS module - APIM - IC - Occupant Classification System Module (OCSM) - PCM - Restraints Control Module (RCM) - Transmission Control Module (TCM) (if equipped) Network Termination The CAN 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 120 ohm resistor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2793 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 IC 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 IC is the only module on this vehicle that has this ability. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Special Tools Used With Diagnostics Communications Network Principles Of Operation Communications Network Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). Vehicle communication utilizes both Medium Speed (MS) and High Speed (HS) 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 Controller Area Network (MS-CAN) - High Speed Controller Area Network (HS-CAN) Medium Speed Controller Area Network (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 will not communicate while certain faults are present, but will operate with diminished performance with other faults present. The MS-CAN may remain operational when 1 of the 2 termination resistors are not present. The MS-CAN 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: - Accessory Protocol Interface Module (APIM) (if equipped) - Audio Control Module (ACM) - Driver Seat Module (DSM) (if equipped) - HVAC module (if equipped) - Instrument Cluster (IC) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2796 - Parking Aid Module (PAM) (if equipped) - Power Running Board (PRB) module (if equipped) - Rear Entertainment Module (RETM) (if equipped) - Satellite Digital Audio Receiver System (SDARS) module (if equipped) - Smart Junction Box (SJB) The following fault chart describes the specific MS-CAN failures and their resulting symptom: Medium Speed Controller Area Network (MS-CAN) Communication Fault Chart High Speed Controller Area Network (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 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 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. The following modules are on the HS-CAN: - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) (if equipped) - Instrument Cluster (IC) - Occupant Classification System Module (OCSM) - PCM - Restraints Control Module (RCM) - Transmission Control Module (TCM) (if equipped) The following fault chart describes the specific HS-CAN failures and their resulting symptom: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2797 High Speed Controller Area Network (HS-CAN) Communication Fault Chart The following chart describes the specific CAN messages broadcast by each module, and the module(s) that receive the message: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2798 CAN Module Commnication Message Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2799 CAN Module Commnication Message Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2800 CAN Module Commnication Message Chart (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2801 CAN Module Commnication Message Chart (Part 4) CAN Module Commnication Message Chart (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2802 Inspection And Verification Communications Network Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. - If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. Visual Inspection Chart 3. Connect the scan tool to the DLC. - NOTE: Make sure to use the latest scan tool software release. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the DLC are provided to the VCM. If the Integrated Diagnostic System (IDS) 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 U, to diagnose No Power To The Scan Tool. See: Pinpoint Tests/Pinpoint Test U: No Power To The Scan Tool 4. Establish a scan tool session. - NOTE: 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. If an IDS session cannot be established with the vehicle, (IDS may state "No communication can be established with the PCM"): Choose "NO" when the scan tool prompts whether or not to retry communication. - Enter either a PCM part number, tear tag or calibration number to identify the vehicle and start a session (the PCM part number and Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2803 4-character tear tag are printed on the PCM label). - Go To Pinpoint Test A, to diagnose "The PCM Does Not Respond To The Scan Tool". See: Pinpoint Tests/Pinpoint Test A: The PCM Does Not Respond To The Scan Tool 5. 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 diagnose the failed communication network. See: Symptom Related Diagnostic Procedures - If a module fails to communicate during the network test, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures 6. Retrieve and review the DTCs. - If the DTCs retrieved are related to the concern, go to DTC Charts. Follow the non-network DTC diagnostics (B-codes, C-codes, P-codes) prior to the network DTC diagnostics (U-codes). For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Diagnostic Trouble Code Descriptions/Communications Network See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart - If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Special Tools Used With Diagnostics Module Configuration Principles Of Operation Module Configuration Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). 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 incorrect operation and/or DTCs setting. 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. To carry out PMI, refer to Programmable Module Installation (PMI) See: Programming and Relearning. NOTE: It is important that the scan tool identifies the vehicle and obtains configuration data prior to removing any modules. The new module must be Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2804 able to communicate with the scan tool in order to carry out PMI. See: Programming and Relearning Module Reprogramming Module reprogramming (also referred to as "flashing") is a scan tool process which updates the strategy/calibration in a module. Reprogramming a module with the same level of software will not improve module operation or repair a hardware failure. Module reprogramming is automatically carried out during PMI when a later strategy/calibration is available. NOTE: Module reprogramming should be limited to circumstances where a published TSB procedure recommends doing so. NOTE: 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 the reprogramming process. Accessory Protocol Interface Module (APIM) Programming APIM programming is a process that updates the APIM Consumer Interface Processor (CIP) and Vehicle Interface Processor (VIP) software. The VIP programming updates the calibration files in the portion of the APIM that interfaces with the Controller Area Network (CAN). The CIP programming updates calibration files in the portion of the APIM that interfaces with mobile phones and other customer devices. APIM programming uses the VCM to read and program the VIP software through the Data Link Connector (DLC). A web-based OASIS application is used to read and program the CIP software via a Universal Serial Bus (USB) cable between the scan tool and vehicle USB port. Both the VCM and OASIS application must be running on the scan tool during APIM programming. To carry out APIM programming, refer to Accessory Protocol Interface Module (APIM) Programming See: Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming. 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 Block Some PCMs contain a memory area called a vehicle identification block. The PCM vehicle identification block commonly stores powertrain configuration items such as Vehicle Identification Number (VIN), tire size, axle ratio, and whether or not the vehicle is equipped with speed control. Module Address A unique module address is assigned to each module on the network for identification. 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 does not reflect customer preference items that have been changed from the default state. These items 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. The following chart lists As-Built data addresses and describes specific module configuration information: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2805 Module Configuration and Parameter Chart (Part 1) Module Configuration and Parameter Chart (Part 2) Inspection And Verification Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2806 Module Configuration Inspection and Verification This provides step-by-step module configuration procedures. Carry out the Programmable Module Installation (PMI) procedure when another diagnostic/repair information directs to carry out configuration or when DTCs from the below list are present: See: Programming and Relearning NOTE: Some of these modules utilize a 5-character DTC followed by a 2-character failure-type code. The failure-type code provides information about specific fault conditions such as opens, or shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2807 Information Bus: Diagnostic Trouble Code Descriptions Communications Network Communications Network DTC Charts NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged wiring or low battery voltage occurrences. Additionally, vehicle service procedures such as module reprogramming will often set network DTCs. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To prevent repeat network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle battery, refer to Battery. NOTE: Some modules on this vehicle utilize a 5-character DTC followed by a 2-character failure-type code. The failure-type code provides information about specific fault conditions such as opens, or shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2808 U0073-U0155 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2809 U016A:00-U0196 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2810 U046B:00-U1900 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2811 U1900-U3000:88 Module Configuration Module Configuration Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2812 B2477-B2900 / P0602-P1639 / U201A:51-U2050 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2813 U2051-U2101:00 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2814 Information Bus: Symptom Related Diagnostic Procedures Communications Network Symptom Chart Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2815 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2816 Symptom Chart (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2817 Information Bus: Pinpoint Tests Pinpoint Test A: The PCM Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test A: The PCM Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 23, Electronic Engine Controls - 4.0L for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 24, Electronic Engine Controls - 4.6L for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - PCM PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- A1 VERIFY WHETHER OTHER HS-CAN MODULES PASS THE NETWORK TEST - Enter the following diagnostic mode on the scan tool: Network Test. - In the left hand pane of the Integrated Diagnostic System (IDS) network test display screen, verify whether any HS-CAN modules passed the network test. - Is the text "pass" or a DTC listed next to any of the following modules (if equipped): 4x4 control module, ABS module, Accessory Protocol Interface Module (APIM), Instrument Cluster (IC), Occupant Classification System Module (OCSM), PCM or Restraints Control Module (RCM)? Yes If "pass" or a DTC was listed next to the PCM, a network fault is not currently present. Go To Pinpoint Test T to diagnose an intermittent HS-CAN fault condition. See: Pinpoint Test T: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Respond If "pass" or a DTC was listed next to one or more modules other than the PCM, GO to A2. No No modules are currently communicating on the HS-CAN. Go To Pinpoint Test s to diagnose no HS-CAN communication. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------- A2 COMPUTERS AND CONTROL SYSTEMS INFORMATION PINPOINT TEST QA VERIFICATION CHECK - Verify that pinpoint test QA has been performed. - Has pinpoint test QA been performed? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2818 Yes GO to A3. No REFER to Computers and Control Systems Information, Pinpoint Tests, pinpoint test QA to diagnose no communication with the PCM. ------------------------------------------------- A3 CHECK THE HS-CAN TERMINATION RESISTANCE - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the Data Link Connector (DLC) C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 54 and 66 ohms? Yes CONNECT the negative battery cable. GO to A5. No GO to A4. ------------------------------------------------- A4 CHECK THE CAN CIRCUITS BETWEEN THE DLC AND THE PCM FOR AN OPEN - Disconnect: PCM C175b. - Measure the resistance between the PCM C175b-11, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the PCM C175b-23, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to A5. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2819 No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- A5 CHECK FOR CORRECT PCM OPERATION - Disconnect all the PCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PCM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test B: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test B: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 30, Transmission Controls - 6R60 for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The 6R60 transmission utilizes a Transmission Control Module (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. Voltage for the TCM is provided by circuits SBB27 (BU/RD) and CE517 (BU/GN). Circuit GD113 (BK/YE) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TCM PINPOINT TEST B: THE TCM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- B1 CHECK THE TCM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2820 - Disconnect: TCM C1575 (6R60 Transmission). - Ignition ON. - Measure the voltage between the TCM C1575-9, circuit CE517 (BU/GN), harness side and ground; and between the TCM C1575-14, circuit SBB27 (BU/RD), harness side and ground - Are the voltages greater than 10 volts? Yes GO to B2. No VERIFY that the Battery Junction Box (BJB) fuse 27 (20A) or Smart Junction Box (SJB) fuse 9 (2A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- B2 CHECK THE TCM GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the TCM C1575-13, circuit GD113 (BK/YE), harness side and ground; and between the TCM C1575-16, circuit GD113 (BK/YE), harness side and ground. Are the resistances less than 5 ohms? Yes GO to B3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- B3 CHECK THE HS-CAN CIRCUITS BETWEEN THE TCM AND THE DLC FOR AN OPEN - Measure the resistance between the TCM C1575-6, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2821 - Measure the resistance between the TCM C1575-2, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to B4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- B4 CHECK FOR CORRECT TCM OPERATION - Disconnect the TCM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the TCM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new TCM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test C: The ABS Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test C: The ABS Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 42, Vehicle Dynamic Systems for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2822 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. 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). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ABS module PINPOINT TEST C: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- C1 CHECK THE ABS VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: ABS Module C155. - Ignition ON. - Measure the voltage between the ABS module, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to C2. No VERIFY the Battery Junction Box (BJB) fuse 6 (40A) or fuse 33 (30A) and the Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- C2 CHECK THE ABS GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the ABS module C155-16, circuit GD120 (BK/GN) harness side and ground. - Is the resistance less than 5 ohms? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2823 GO to C3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- C3 CHECK THE HS-CAN CIRCUITS BETWEEN THE ABS MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the ABS module C135-12, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the ABS module C135-13, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to C4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- C4 CHECK FOR CORRECT ABS MODULE OPERATION - Disconnect the ABS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the ABS module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ABS module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2824 Communications Network Pinpoint Tests Pinpoint Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 46, Supplemental Restraint System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Restraints Control Module (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. Voltage for the RCM is provided by circuit CBP17 (BN/GN), and the RCM is case grounded. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Case ground open - RCM PINPOINT TEST D: THE RCM DOES NOT RESPOND TO THE SCAN TOOL WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- D1 CHECK THE RCM CONNECTION - Ignition OFF. - Depower the SRS. Refer to Air Bag Systems. - Disconnect: RCM C310a. - Disconnect: RCM C310b. - Are RCM C310a pin 24 and RCM C310b pins 17 and 18 OK? Yes GO to D2. No REPAIR the RCM connector pins as necessary. REPOWER the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D2 CHECK THE RCM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2825 - Deactivate the SRS. Refer to Air Bag Systems. - Repower the SRS. Refer to Air Bag Systems. - Ignition ON. - Measure the voltage between the RCM C310a-24, circuit CBP17 (BN/GN), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to D3. No VERIFY the Smart Junction Box (SJB) fuse 17 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D3 CHECK THE RCM CASE GROUND - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the RCM case and a good chassis ground. - Is the resistance less than 5 ohms? Yes GO to D4. No REPAIR the RCM case ground as necessary. CONNECT the negative battery cable. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D4 CHECK THE HS-CAN CIRCUITS BETWEEN THE RCM AND THE DLC FOR AN OPEN - Measure the resistance between the RCM C310b-18, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the RCM C310b-17, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2826 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to D5. No REPAIR the circuit in question. CONNECT the negative battery cable. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- D5 CHECK FOR CORRECT RCM OPERATION - Disconnect all the RCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the RCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new RCM. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test E: The 4X4 Control Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test E: The 4X4 Control Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 34, Four Wheel Drive Systems for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The 4X4 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 4X4 control module. 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). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2827 - 4X4 control module PINPOINT TEST E: THE 4X4 CONTROL MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- E1 CHECK THE 4X4 CONTROL MODULE VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: 4X4 Control Module C281a. - Disconnect: 4X4 Control Module C281b. - Ignition ON. - Measure the voltage between the 4X4 control module, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to E2. No VERIFY the Battery Junction Box (BJB) fuse 23 (20A) or fuse 26 (20A) is OK and the Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- E2 CHECK THE 4X4 CONTROL MODULE GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the 4X4 control module, harness side and ground as follows: - Are the resistances less than 5 ohms? Yes GO to E3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- E3 CHECK THE HS-CAN CIRCUITS BETWEEN THE 4X4 CONTROL MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the 4X4 control module C281a-10, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2828 - Measure the resistance between the 4X4 control module C281a-9, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to E4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- E4 CHECK FOR CORRECT 4X4 CONTROL MODULE OPERATION - Disconnect all the 4X4 control module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the 4X4 control module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new 4X4 control module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2829 Refer to Wiring Diagram Set 46, Supplemental Restraint System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Occupant Classification System Module (OCSM) 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 OCSM. Voltage to the OCSM is supplied by circuit CBP17 (BN/GN). Ground is supplied by circuit GD145 (BK/BU). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - OCSM PINPOINT TEST F: THE OCSM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification ------------------------------------------------- F1 CHECK THE OCSM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. - Ignition OFF. - Depower the SRS. Refer to Air Bag Systems. - Disconnect: OCSM C3159. - Deactivate the SRS. Refer to Air Bag Systems. - Repower the SRS. Refer to Air Bag Systems. - Ignition ON. - Measure the voltage between the OCSM C3159-1, circuit CBP17 (BN/GN), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to F2. No VERIFY the Smart Junction Box (SJB) fuse 17 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F2 CHECK THE OCSM GROUND CIRCUIT FOR AN OPEN Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2830 - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the OCSM C3159-14, circuit GD145 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to F3. No REPAIR the circuit. CONNECT the negative battery cable. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F3 CHECK THE HS-CAN CIRCUITS BETWEEN THE OCSM AND THE DLC FOR AN OPEN - Measure the resistance between the OCSM C3159-18, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the OCSM C3159-9, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to F4. No REPAIR the circuit. REACTIVATE the SRS. REFER to Air Bag Systems. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- F4 CHECK FOR CORRECT OCSM OPERATION - Disconnect the OCSM connector. - Check for: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2831 - corrosion - damaged pins - pushed-out pins - Connect the OCSM connector and make sure it seats correctly. - Verify the concern is still present. Is the concern still present? Yes INSTALL a new OCSM. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. REACTIVATE the SRS. REFER to Air Bag Systems. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 60, Instrument Cluster for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Instrument Cluster (IC) 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 connection to the IC and circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN connection to the IC. Voltage for the IC is provided by circuits CDC34 (WH/OG) and SBP24 (VT/RD). Circuit GD145 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - IC PINPOINT TEST G: THE IC DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- G1 CHECK THE HS-CAN TERMINATION RESISTANCE - Ignition OFF. - Disconnect: Negative Battery Cable. - Disconnect the scan tool cable from the Data Link Connector (DLC). - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2832 - Is the resistance between 54 and 66 ohms? Yes GO to G2. No GO to G4. ------------------------------------------------- G2 CHECK THE IC GROUND CIRCUIT FOR AN OPEN - Measure the resistance between the IC C220-13, circuit GD145 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to G3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G3 CHECK THE IC VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Disconnect: IC C220. - Ignition ON. - Measure the voltage between the IC, harness side and ground as follows: - Are the voltages greater than 10 volts? Yes GO to G5. No VERIFY the Smart Junction Box (SJB) fuse 8 (15A) or fuse 24 (10A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G4 CHECK THE HS-CAN CIRCUITS BETWEEN THE IC AND THE DLC FOR AN OPEN - Measure the resistance between the IC C220-7, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2833 - Measure the resistance between the IC C220-8, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes GO to G5. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- G5 CHECK THE MS-CAN CIRCUITS BETWEEN THE IC AND THE DLC FOR AN OPEN - Measure the resistance between the IC C220-4, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the IC C220-5, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to G6. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2834 G6 CHECK FOR CORRECT IC OPERATION - Disconnect the IC connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the IC connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new IC. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test H: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test H: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 10, Grounds for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 13, Power Distribution/SJB for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (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. Voltage for the SJB is provided by circuit SBB03 (BU/RD). Circuit GD108 (BK/VT) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - SJB PINPOINT TEST H: THE SJB DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- H1 CHECK THE SJB FUSE FOR VOLTAGE - Ignition OFF. - NOTE: Measurements are taken with the fuses installed. - Measure the voltage between the SJB fuse 2 (5A) and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2835 - Are the voltages greater than 10 volts? Yes GO to H3. No VERIFY the Smart Junction Box (SJB) fuse 2 (5A) is OK. If OK, GO to H2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H2 CHECK THE SJB VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: SJB C2280e. - Measure the voltage between the SJB C2280e-1, circuit SBB03 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to H5. No VERIFY the Battery Junction Box (BJB) fuse 3 (50A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H3 CHECK THE SJB GROUND CIRCUIT FOR AN OPEN - Disconnect: Negative Battery Cable. - Disconnect: SJB C2280e. - Measure the resistance between the SJB C2280e-22, circuit GD108 (BK/VT), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to H4. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2836 No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H4 CHECK THE MEDIUM SPEED CAN CIRCUITS BETWEEN THE SJB AND THE DLC FOR AN OPEN - Disconnect: SJB C2280d. - Measure the resistance between the SJB C2280d-16, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SJB C2280d-15, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to H5. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- H5 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test I: The HVAC Module Does Not Respond To The Scan Tool Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2837 Communications Network Pinpoint Tests Pinpoint Test I: The HVAC Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 55, Automatic Climate Control System for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The HVAC 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 HVAC module. Voltage for the HVAC module is provided by circuits CBP20 (YE/VT) and SBP28 (GN/RD). Circuit GD145 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - HVAC module PINPOINT TEST I: THE HVAC MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- I1 CHECK THE HVAC MODULE VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: HVAC Module C228a. - Ignition ON. - Measure the voltage between the HVAC module C228a-13, circuit SBP28 (GN/RD), and between the HVAC module C228a-3, circuit CBP20 (YE/VT) and ground. - Are the voltages greater than 10 volts? Yes GO to I2. No VERIFY the Smart Junction Box (SJB) fuse 20 (10A) or fuse 28 (10A) is OK. If OK, REPAIR the circuit in question. CLEAR the DTCs. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. REPEAT the network test with the scan tool. ------------------------------------------------- I2 CHECK THE HVAC GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2838 - Measure the resistance between the HVAC module C228a-2, circuit GD145 (BK/BU) and ground. - Is the resistance less than 5 ohms? Yes GO to I3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- I3 CHECK THE MS-CAN CIRCUITS BETWEEN THE HVAC MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the HVAC module C228a-11, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the HVAC module C228a-1, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to I4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- I4 CHECK FOR CORRECT HVAC MODULE OPERATION - Disconnect all the HVAC module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the HVAC module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2839 - Is the concern still present? Yes INSTALL a new HVAC module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test J: The Audio Control Module (ACM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test J: The Audio Control Module (ACM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 130, Audio System/Navigation for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the network connection to the Audio Control Module (ACM). Voltage for the ACM is provided by circuits CBP12 (GN/WH) and SBP03 (BU/RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - ACM PINPOINT TEST J: THE ACM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- J1 CHECK THE ACM VOLTAGE SUPPLY CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: ACM C290a. - Ignition ON. - Measure the voltage between the ACM C290a-1, circuit SBP03 (BU/RD), harness side and ground; and between the ACM C290a-2, circuit CBP12 (GN/WH), harness side and ground. - Are the voltages greater than 10 volts? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2840 GO to J2. No VERIFY the Smart Junction Box (SJB) fuse 3 (20A) or fuse 12 (5A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- J2 CHECK THE ACM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the ACM C290a-13, circuit GD114 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to J3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- J3 CHECK THE MS-CAN CIRCUITS BETWEEN THE ACM AND THE DLC FOR AN OPEN - Measure the resistance between the ACM C290b-15, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the base ACM C290b-16, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to J4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- J4 CHECK FOR CORRECT ACM OPERATION - Disconnect all the ACM connectors. - Check for: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2841 - corrosion - damaged pins - pushed-out pins - Connect all the ACM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new ACM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 130, Audio System/Navigation for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Satellite Digital Audio Receiver System (SDARS) 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 SDARS module. Voltage for the SDARS module is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - SDARS module PINPOINT TEST K: THE SDARS MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- K1 CHECK THE SDARS MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: SDARS Module C3290. - Ignition ON. - Measure the voltage between the SDARS module C3290-9, circuit SBB41 (RD), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2842 - Is the voltage greater than 10 volts? Yes GO to K2. No VERIFY the Battery Junction Box (BJB) fuse 41 (15A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- K2 CHECK THE SDARS MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the SDARS module C3290-3, circuit GD114 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to K3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- K3 CHECK THE MS-CAN CIRCUITS BETWEEN THE SDARS MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the SDARS module C3290-1, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SDARS module C3290-7, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2843 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to K4. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- K4 CHECK FOR CORRECT SDARS MODULE OPERATION - Disconnect the SDARS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the SDARS module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SDARS module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 130, Audio System/Navigation for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Rear Entertainment Module (RETM) 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 RETM. The RETM is only on vehicles equipped with rear seat entertainment. Voltage for the RETM is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - RETM Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2844 PINPOINT TEST L: THE RETM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- L1 CHECK THE RETM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: RETM C9029. - Ignition ON. - Measure the voltage between the RETM C9029-16, circuit SBB41 (RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to L2. No VERIFY the Battery Junction Box (BJB) fuse 41 (15A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- L2 CHECK THE RETM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the RETM C9029-1, circuit GD114 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to L3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- L3 CHECK THE MS-CAN CIRCUITS BETWEEN THE RETM AND THE DLC FOR AN OPEN - Measure the resistance between the RETM C9029-8, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2845 - Measure the resistance between the RETM C9029-7, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to L4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- L4 CHECK FOR CORRECT RETM OPERATION - Disconnect the RETM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the RETM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new RETM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test M: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test M: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 123, Memory Seats for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2846 Normal Operation The Driver Seat Module (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. Voltage for the DSM is provided by circuit SBP01 (RD). Circuit GD143 (BK/OG) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - DSM PINPOINT TEST M: THE DSM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- M1 CHECK THE DSM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: DSM C341c. - Ignition ON. - Measure the voltage between the DSM C341c-1, circuit SBP01 (RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to M2. No VERIFY the Smart Junction Box (SJB) fuse 1 (20A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- M2 CHECK THE DSM GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the DSM C341c-13, circuit GD143 (BK/OG), harness side and ground. - Is the resistance less than 5 ohms? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2847 GO to M3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- M3 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC AND THE DSM FOR AN OPEN - Measure the resistance between the DSM C341c-11, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the DSM C341c-12, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to M4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- M4 CHECK FOR CORRECT DSM OPERATION - Disconnect all the DSM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the DSM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new DSM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test N: The Power Running Board Module Does Not Respond To The Scan Tool Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2848 Communications Network Pinpoint Tests Pinpoint Test N: The Power Running Board Module Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Power Running Board (PRB) 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 PRB module. Voltage for the PRB module is provided by circuit SBB19 (BU/RD). Circuit GD151 (BK/GN) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PRB module PINPOINT TEST N: THE PRB MODULE DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- N1 CHECK THE PRB MODULE VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: PRB Module C4322b. - Ignition ON. - Measure the voltage between the PRB module C4322b-1, circuit SBB19 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to N2. No VERIFY the Battery Junction Box (BJB) fuse 19 (30A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- N2 CHECK THE PRB MODULE GROUND CIRCUIT FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the PRB module C4322b-4, circuit GD151 (BK/GN), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2849 - Is the resistance less than 5 ohms? Yes GO to N3. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- N3 CHECK THE MS-CAN CIRCUITS BETWEEN THE PRB MODULE AND THE DLC FOR AN OPEN - Measure the resistance between the PRB module C4322b-8, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the PRB module C4322b-7, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to N4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- N4 CHECK FOR CORRECT PRB MODULE OPERATION - Disconnect all the PRB module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PRB module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2850 Yes INSTALL a new PRB module. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test O: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test O: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 131, Parking Aid for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Parking Aid Module (PAM) 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 PAM. Voltage for the PAM is provided by circuit CBP18 (GY/OG). Circuit GD145 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - PAM PINPOINT TEST O: THE PAM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- O1 VERIFY PARKING AID SYSTEM TYPE - NOTE: The Explorer uses a radar parking aid system while the Mountaineer and Explorer Sport Trac use an ultrasonic system. - Verify the parking aid system. - Is the vehicle equipped with a RADAR parking aid system? Yes GO to O2. No GO to O5 . ------------------------------------------------- O2 CHECK THE PAM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN (RADAR) - Ignition OFF. - Disconnect: PAM C4226. - Ignition ON. - Measure the voltage between the PAM C4226-18, circuit CBP18 (GY/OG), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2851 - Is the voltage greater than 10 volts? Yes GO to O3. No VERIFY the Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O3 CHECK THE PAM GROUND CIRCUIT FOR AN OPEN (RADAR) - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the PAM C4226-6, circuit GD145 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to O4. No REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O4 CHECK THE MS-CAN CIRCUITS BETWEEN THE PAM AND THE DLC FOR AN OPEN (RADAR) - Measure the resistance between the PAM C4226-4, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the PAM C4226-5, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2852 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to O8. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O5 CHECK THE PAM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN (ULTRASONIC) - Ignition OFF. - Disconnect: PAM C4014 (Mountaineer) or C3267 (Explorer Sport Trac). - Ignition ON. - Measure the voltage between the PAM C4014-1 (Mountaineer) or C3267-1 (Explorer Sport Trac), circuit CBP18 (GY/OG), harness side and ground. Is the voltage greater than 10 volts? Yes GO to O6. No VERIFY the Smart Junction Box (SJB) fuse 18 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O6 CHECK THE PAM GROUND CIRCUIT FOR AN OPEN (ULTRASONIC) - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the PAM C4014-4 (Mountaineer) or C3267-4 (Explorer Sport Trac), circuit GD145 (BK/BU), harness side and ground. - Is the resistance less than 5 ohms? Yes GO to O7. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2853 REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O7 CHECK THE MS-CAN CIRCUITS BETWEEN THE PAM AND THE DLC FOR AN OPEN (ULTRASONIC) - Measure the resistance between the PAM C4014-3 (Mountaineer) or C3267-3 (Explorer Sport Trac), circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the PAM C4014-11 (Mountaineer) or C3267-11 (Explorer Sport Trac), circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to O8. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- O8 CHECK FOR CORRECT PAM OPERATION - Disconnect the PAM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the PAM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PAM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool Communications Network Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2854 Pinpoint Tests Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Accessory Protocol Interface Module (APIM) 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 connection to the APIM. Circuits VDB06 (GY/OG) (MS-CAN +) and VDB07 (VT/OG) (MS-CAN -) provide the MS-CAN connection to the APIM. Voltage for the APIM is provided by circuit SBB41 (RD). Circuit GD114 (BK/BU) provides ground. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - APIM PINPOINT TEST P: THE APIM DOES NOT RESPOND TO THE SCAN TOOL NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- P1 CHECK THE APIM VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: APIM C3342. - Ignition ON. - Measure the voltage between the APIM C3342-1, circuit SBB41 (RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to P2. No VERIFY the BJB fuse 41 (15A) is OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P2 CHECK THE APIM GROUND CIRCUITS FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the APIM C3342-37, circuit GD114 (BK/BU), harness side and ground; and between the APIM C3342-38, circuit GD114 (BK/BU), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2855 - Are the resistances less than 5 ohms? Yes GO to P3. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P3 CHECK THE HS-CAN CIRCUITS BETWEEN THE APIM AND THE DLC FOR AN OPEN - Measure the resistance between the APIM C3342-53, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the APIM C3342-54, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Are the resistances less than 5 ohms? Yes GO to P4. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P4 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC AND THE APIM FOR AN OPEN - Measure the resistance between the APIM C3342-16, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2856 - Measure the resistance between the APIM C3342-17, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to P5. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- P5 CHECK FOR CORRECT APIM OPERATION - Disconnect all the APIM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the APIM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new APIM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Q1-Q27 Communications Network Pinpoint Tests Pinpoint Test Q: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2857 The Medium Speed Controller Area Network (MS-CAN) uses an unshielded twisted pair cable, circuits VDB06 (GY/OG) and VDB07 (VT/OG) provide the network connection to all modules on the network. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Accessory Protocol Interface Module (APIM) (if equipped) - Audio Control Module (ACM) - Driver Seat Module (DSM) (if equipped) - HVAC module (if equipped) - Instrument Cluster (IC) - Parking Aid Module (PAM) (if equipped) - Power Running Board (PRB) module (if equipped) - Rear Entertainment Module (RETM) (if equipped) - Satellite Digital Audio Receiver System (SDARS) module (if equipped) - Smart Junction Box (SJB) PINPOINT TEST Q: NO MS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Q1 CHECK THE DLC PINS FOR DAMAGE - Ignition OFF. - Disconnect the scan tool cable from the Data Link Connector (DLC). - Inspect DLC pins 3 and 11 for damage. - Are DLC pins 3 and 11 OK? Yes GO to Q2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q2 CHECK THE MS-CAN TERMINATION RESISTANCE - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance between 54 and 66 ohms? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2858 Yes GO to Q3. No GO to Q5. ------------------------------------------------- Q3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes GO to Q4. No GO to Q28. ------------------------------------------------- Q4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Connect: Negative Battery Cable. - Ignition ON. - Measure the voltage between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Is the voltage greater than 6 volts? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool. No The CAN has tested within specifications. Go To Pinpoint Test R to diagnose the intermittent MS-CAN fault. See: Pinpoint Test R: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Respo ------------------------------------------------- Q5 CHECK THE MS-CAN TERMINATION RESISTOR - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2859 - Is the resistance between 108 and 132 ohms? Yes GO to Q6. No GO to Q9. ------------------------------------------------- Q6 CHECK THE MS-CAN TERMINATION RESISTOR WITH THE SJB DISCONNECTED - Disconnect: SJB C2280b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance between 108 and 132 ohms? Yes GO to Q7. No GO to Q8. ------------------------------------------------- Q7 CHECK THE MS-CAN CIRCUITS BETWEEN THE SJB AND THE DLC FOR AN OPEN - Measure the resistance between the SJB C2280d-16, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the SJB C2280d-15, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2860 Yes CONNECT the negative battery cable. GO to Q54. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q8 CHECK THE MS-CAN CIRCUITS BETWEEN THE IC AND THE DLC FOR AN OPEN - Disconnect: IC C220. - Measure the resistance between the IC C220-4, circuit VDB06 (GY/OG), harness side and the DLC C251-3, circuit VDB06 (GY/OG), harness side. - Measure the resistance between the IC C220-5, circuit VDB07 (VT/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to Q45. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q9 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q11. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2861 GO to Q10. ------------------------------------------------- Q10 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR AN OPEN - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance greater than 10,000 ohms? Yes REPAIR the DLC or REPAIR the circuit in question. CONNECT the negative battery cable. VERIFY the scan tool operation on a substitute vehicle. CLEAR the DTCs. REPEAT the network test on the suspect vehicle. No A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5 minutes. REPEAT the pinpoint test. ------------------------------------------------- Q11 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE IC DISCONNECTED - Disconnect: ICC220. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q12. No CONNECT the negative battery cable. GO to Q45. ------------------------------------------------- Q12 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE ACM DISCONNECTED - Disconnect: ACMC290b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q13. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2862 No CONNECT the negative battery cable. GO to Q46. ------------------------------------------------- Q13 VERIFY VEHICLE EQUIPMENT - HVAC MODULE - Inspect the vehicle for an HVAC module. - Is the vehicle equipped with an HVAC module? Yes GO to Q14. No GO to Q15. ------------------------------------------------- Q14 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE HVAC MODULE DISCONNECTED - Disconnect: HVAC Module C228a. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q15. No CONNECT the negative battery cable. GO to Q47. ------------------------------------------------- Q15 VERIFY VEHICLE EQUIPMENT - RETM - Inspect the vehicle for an RETM. - Is the vehicle equipped with an RETM? Yes GO to Q16. No GO to Q17. ------------------------------------------------- Q16 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE RETM DISCONNECTED - Disconnect: RETM C9029. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2863 - Is the resistance less than 5 ohms? Yes GO to Q17. No CONNECT the negative battery cable. GO to Q48. ------------------------------------------------- Q17 VERIFY VEHICLE EQUIPMENT - DSM - Inspect the vehicle for a DSM. - Is the vehicle equipped with a DSM? Yes GO to Q18. No GO to Q19. ------------------------------------------------- Q18 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE DSM DISCONNECTED - Disconnect: DSM C341c. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q19. No CONNECT the negative battery cable. GO to Q49. ------------------------------------------------- Q19 VERIFY VEHICLE EQUIPMENT - SDARS MODULE - Inspect the vehicle for a SDARS module. - Is the vehicle equipped with a SDARS module? Yes GO to Q20. No GO to Q21. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2864 ------------------------------------------------- Q20 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE SDARS MODULE DISCONNECTED - Disconnect: SDARS C3290. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q21. No CONNECT the negative battery cable. GO to Q50. ------------------------------------------------- Q21 VERIFY VEHICLE EQUIPMENT - PRB MODULE - Inspect the vehicle for a PRB module. - Is the vehicle equipped with a PRB module? Yes GO to Q22. No GO to Q23. ------------------------------------------------- Q22 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE PRB MODULE DISCONNECTED - Disconnect: PRB Module C4322b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q23. No CONNECT the negative battery cable. GO to Q51. ------------------------------------------------- Q23 VERIFY VEHICLE EQUIPMENT - PAM - Inspect the vehicle for a PAM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2865 - Is the vehicle equipped with a PAM? Yes GO to Q24. No GO to Q25. ------------------------------------------------- Q24 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE PAM DISCONNECTED - Disconnect: PAM C4014 (Mountaineer), C3267 (Explorer Sport Trac) or C4226 (Explorer). - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q25. No CONNECT the negative battery cable. GO to Q52. ------------------------------------------------- Q25 VERIFY VEHICLE EQUIPMENT - APIM - Inspect the vehicle for an APIM. - Is the vehicle equipped with an APIM? Yes GO to Q26. No GO to Q27. ------------------------------------------------- Q26 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE APIM DISCONNECTED - Disconnect: APIM C3342. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes GO to Q27. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2866 No CONNECT the negative battery cable.GO to Q53. ------------------------------------------------- Q27 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE SJB DISCONNECTED - Disconnect: SJB C2280d. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance less than 5 ohms? Yes REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No CONNECT the negative battery cable. GO to Q54. ------------------------------------------------Q28-Q54 Communications Network Pinpoint Tests Pinpoint Test Q: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Medium Speed Controller Area Network (MS-CAN) uses an unshielded twisted pair cable, circuits VDB06 (GY/OG) and VDB07 (VT/OG) provide the network connection to all modules on the network. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Accessory Protocol Interface Module (APIM) (if equipped) - Audio Control Module (ACM) - Driver Seat Module (DSM) (if equipped) - HVAC module (if equipped) - Instrument Cluster (IC) - Parking Aid Module (PAM) (if equipped) - Power Running Board (PRB) module (if equipped) - Rear Entertainment Module (RETM) (if equipped) - Satellite Digital Audio Receiver System (SDARS) module (if equipped) - Smart Junction Box (SJB) PINPOINT TEST Q: NO MS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2867 test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Q28 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE IC DISCONNECTED - Disconnect: ICC220. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q45. No GO to Q29. ------------------------------------------------- Q29 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE ACM DISCONNECTED - Disconnect: ACM C290b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q46. No GO to Q30. ------------------------------------------------- Q30 VERIFY VEHICLE EQUIPMENT - HVAC MODULE - Inspect the vehicle for an HVAC module. - Is the vehicle equipped with an HVAC module? Yes GO to Q31. No GO to Q32. ------------------------------------------------- Q31 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE HVAC MODULE Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2868 DISCONNECTED - Disconnect: HVAC Module C228a. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q47. No GO to Q32. ------------------------------------------------- Q32 VERIFY VEHICLE EQUIPMENT - RETM - Inspect the vehicle for a RETM. - Is the vehicle equipped with a RETM? Yes GO to Q33. No GO to Q34. ------------------------------------------------- Q33 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE RETM DISCONNECTED - Disconnect: RETM C9029. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q48. No GO to Q34. ------------------------------------------------- Q34 VERIFY VEHICLE EQUIPMENT - DSM - Inspect the vehicle for a DSM. Is the vehicle equipped with a DSM? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2869 GO to Q35. No GO to Q36. ------------------------------------------------- Q35 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE DSM DISCONNECTED - Disconnect: DSM C341c. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q49. No GO to Q36. ------------------------------------------------- Q36 VERIFY VEHICLE EQUIPMENT - SDARS MODULE - Inspect the vehicle for a SDARS module. Is the vehicle equipped with a SDARS module? Yes GO to Q37. No GO to Q38. ------------------------------------------------- Q37 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE SDARS MODULE DISCONNECTED - Disconnect: SDARS Module C3290. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q50. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2870 GO to Q38. ------------------------------------------------- Q38 VERIFY VEHICLE EQUIPMENT - PRB MODULE - Inspect the vehicle for a PRB module. - Is the vehicle equipped with a PRB module? Yes GO to Q39. No GO to Q40. ------------------------------------------------- Q39 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE PRB MODULE DISCONNECTED - Disconnect: PRB Module C4322b. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q51. No GO to Q40. ------------------------------------------------- Q40 VERIFY VEHICLE EQUIPMENT - PAM - Inspect the vehicle for a PAM. - Is the vehicle equipped with a PAM? Yes GO to Q41. No GO to Q42. ------------------------------------------------- Q41 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE PAM DISCONNECTED - Disconnect: PAM C4014 (Mountaineer), C3267 (Explorer Sport Trac) or C4226 (Explorer). - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2871 - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q52. No GO to Q42. ------------------------------------------------- Q42 VERIFY VEHICLE EQUIPMENT - APIM - Inspect the vehicle for an APIM. - Is the vehicle equipped with an APIM? Yes GO to Q43. No GO to Q44. ------------------------------------------------- Q43 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE APIM DISCONNECTED - Disconnect: APIM C3342. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q53. No GO to Q44. ------------------------------------------------- Q44 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE SJB DISCONNECTED - Disconnect: SJB C2280d. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to Q54. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2872 No REPAIR the circuit in question. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q45 CHECK FOR CORRECT IC OPERATION - Disconnect the IC connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the IC connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new IC. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q46 CHECK FOR CORRECT ACM OPERATION - Disconnect all the ACM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the ACM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ACM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q47 CHECK FOR CORRECT HVAC MODULE OPERATION - Disconnect all the HVAC module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the HVAC module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new HVAC module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2873 The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q48 CHECK FOR CORRECT RETM OPERATION - Disconnect the RETM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the RETM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new RETM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q49 CHECK FOR CORRECT DSM OPERATION - Disconnect all the DSM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the DSM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new DSM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q50 CHECK FOR CORRECT SDARS MODULE OPERATION - Disconnect the SDARS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the SDARS module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new SDARS module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2874 ------------------------------------------------- Q51 CHECK FOR CORRECT PRB MODULE OPERATION - Disconnect all the PRB module connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PRB module connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PRB module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q52 CHECK FOR CORRECT PAM OPERATION - Disconnect the PAM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the PAM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PAM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q53 CHECK FOR CORRECT APIM OPERATION - Disconnect the APIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the APIM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new APIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Q54 CHECK FOR CORRECT SJB OPERATION Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2875 - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test R: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Respo Communications Network Pinpoint Tests Pinpoint Test R: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Responding During Network Test Normal Operation An open circuit VDB06 (GY/OG) (MS-CAN +) or VDB07 (VT/OG) (MS-CAN -) may cause intermittent or unreliable communication to all modules on the Medium Speed Controller Area Network (MS-CAN). The MS-CAN is used for communication between the following modules: - Accessory Protocol Interface Module (APIM) - Audio Control Module (ACM) - Driver Seat Module (DSM) - HVAC module - Instrument Cluster (IC) - Parking Aid Module (PAM) - Power Running Board (PRB) module - Rear Entertainment Module (RETM) - Satellite Digital Audio Receiver System (SDARS) module - Smart Junction Box (SJB) In the event that 1 of the 2 network circuits (MS-CAN + or MS-CAN -) becomes open to a module on the network, unreliable network communication to all modules on the network may result. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors PINPOINT TEST R: INTERMITTENT NO MS-CAN COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING NETWORK TEST NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Various network DTCs will set while disabling modules in this test procedure which will need to be cleared after the diagnostic procedure is completed. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2876 R1 CHECK THE DLC PINS FOR DAMAGE - Ignition OFF. - Disconnect the scan tool cable from the DLC. - Inspect DLC pins 3 and 11 for damage. - Are DLC pins 3 and 11 OK? Yes GO to R2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- R2 CHECK THE MS-CAN TERMINATION RESISTANCE - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and the DLC C251-11, circuit VDB07 (VT/OG), harness side. - Is the resistance between 54 and 66 ohms? Yes GO to R3. No CONNECT the negative battery cable. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool ------------------------------------------------- R3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to R4. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2877 CONNECT the negative battery cable. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool ------------------------------------------------- R4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Ignition ON. - Measure the voltage between the DLC C251-3, circuit VDB06 (GY/OG), harness side and ground; and between the DLC C251-11, circuit VDB07 (VT/OG), harness side and ground. - Are the voltages greater than 6 volts? Yes REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. No GO to R5. ------------------------------------------------- R5 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE HVAC MODULE DISABLED - Disconnect: SJB Fuses 20 (10A) and 28 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test I. See: Pinpoint Test I: The HVAC Module Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to R6. ------------------------------------------------- R6 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE ACM DISABLED - Disconnect: SJB Fuse 3 (20A) and 12 (5A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test J. See: Pinpoint Test J: The Audio Control Module (ACM) Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to R7. ------------------------------------------------- R7 VERIFY VEHICLE EQUIPMENT - DSM - Inspect the vehicle for a DSM. - Is the vehicle equipped with a DSM? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2878 GO to R8. No GO to R9. ------------------------------------------------- R8 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE DSM DISABLED - Disconnect: SJB Fuse 1 (20A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test M. See: Pinpoint Test M: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to R9. ------------------------------------------------- R9 VERIFY VEHICLE EQUIPMENT - PRB MODULE - Inspect the vehicle for power running boards. - Is the vehicle equipped with power running boards? Yes GO to R10. No GO to R11. ------------------------------------------------- R10 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE PRB MODULE DISABLED - Disconnect: BJB Fuse 19 (30A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test N. See: Pinpoint Test N: The Power Running Board Module Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to R11. ------------------------------------------------- R11 VERIFY VEHICLE EQUIPMENT - RETM APIM AND/OR SDARS MODULE - Inspect the vehicle for an RETM, an APIM, and/or a SDARS module. - Is the vehicle equipped with an RETM, an APIM and/or a SDARS module? Yes GO to R12. No GO to R14. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2879 ------------------------------------------------- R12 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE RETM, APIM, AND/OR SDARS MODULE DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: BJB Fuse 41 (15A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. For vehicles equipped with two or more of the following modules: RETM, APIM, SDARS module, GO to R13. For vehicles equipped with a RETM only, Go To Pinpoint Test L. See: Pinpoint Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool For vehicles equipped with a APIM only, Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool For vehicles equipped with a SDARS module only, Go To Pinpoint Test K. See: Pinpoint Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to R16. ------------------------------------------------- R13 VERIFY VEHICLE EQUIPMENT - RETM - Inspect the vehicle for an RETM. - Is the vehicle equipped with an RETM? Yes GO to R14. No GO to R15. ------------------------------------------------- R14 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE RETM DISCONNECTED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: RETM C9029. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes CONNECT the RETM. Go To Pinpoint Test L. See: Pinpoint Test L: The Rear Entertainment Module (RETM) Does Not Respond To The Scan Tool No GO to R15 ------------------------------------------------- R15 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE APIM DISCONNECTED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2880 test results. - Disconnect: APIM C3342. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. Do all other modules pass the network test? Yes CONNECT the APIM. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool No CONNECT the APIM. Go To Pinpoint Test K. See: Pinpoint Test K: The Satellite Digital Audio Receiver System (SDARS) Module Does Not Respond To The Scan Tool ------------------------------------------------- R16 VERIFY VEHICLE EQUIPMENT - PAM - Inspect the vehicle for a PAM. - Is the vehicle equipped with a PAM? Yes GO to R17. No GO to R18. ------------------------------------------------- R17 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE PAM DISABLED - Disconnect: SJB Fuse 18 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test O. See: Pinpoint Test O: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to R18. ------------------------------------------------- R18 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE IC DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuse 8 (15A) and 24 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test G. See: Pinpoint Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool No INSTALL the removed fuses. An intermittent fault is not present. Go To Pinpoint Test Q. See: Pinpoint Test Q: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2881 ------------------------------------------------Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding Communications Network Pinpoint Tests Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable, circuits VDB04 (WH/BU) and VDB05 (WH). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) (if equipped) - Instrument Cluster (IC) - Occupant Classification System Module (OCSM) - PCM - Restraints Control Module (RCM) - Transmission Control Module (TCM) (if equipped) PINPOINT TEST S: NO HS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- S1 CHECK THE DLC PINS FOR DAMAGE - Ignition OFF. - Disconnect the scan tool cable from the Data Link Connector (DLC). - Inspect DLC pins 6 and 14 for damage. - Are DLC pins 6 and 14 OK? Yes GO to S2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S2 CHECK THE HS-CAN TERMINATION RESISTANCE Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2882 - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 54 and 66 ohms? Yes GO to S3. No GO to S5. ------------------------------------------------- S3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes GO to S4. No GO to S19. ------------------------------------------------- S4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Connect: Negative Battery Cable. - Ignition ON. - Measure the voltage between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the voltages greater than 6 volts? Yes REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2883 The CAN has tested within specifications. Go To Pinpoint Test T to diagnose an intermittent HS-CAN fault. See: Pinpoint Test T: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Respond ------------------------------------------------- S5 CHECK THE HS-CAN TERMINATION RESISTOR - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance between 108 and 132 ohms? Yes GO to S6. No GO to S9. ------------------------------------------------- S6 CHECK THE HS-CAN TERMINATION RESISTOR WITH THE PCM DISCONNECTED - Disconnect: PCM C175b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Is the resistance between 108 and 132 ohms? Yes GO to S7. No GO to S8. ------------------------------------------------- S7 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM AND THE DLC FOR AN OPEN - Measure the resistance between the PCM C175b-11, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the PCM C175b-23, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2884 - Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to S27. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S8 CHECK THE HS-CAN CIRCUITS BETWEEN THE IC AND THE DLC FOR AN OPEN - Measure the resistance between the IC C220-7, circuit VDB04 (WH/BU), harness side and the DLC C251-6, circuit VDB04 (WH/BU), harness side. - Measure the resistance between the IC C220-8, circuit VDB05 (WH), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Are the resistances less than 5 ohms? Yes CONNECT the negative battery cable. GO to S34. No REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S9 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2885 Yes GO to S11. No GO to S10. ------------------------------------------------- S10 CHECK THE HS-CAN CIRCUITS FOR AN OPEN AT THE DLC - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance greater than 10,000 ohms? Yes REPAIR the DLC or REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5 minutes. REPEAT the pinpoint test. ------------------------------------------------- S11 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE PCM DISCONNECTED - Disconnect: PCM C175b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S12. No CONNECT the negative battery cable. GO to S27. ------------------------------------------------- S12 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE ABS MODULE DISCONNECTED - Disconnect: ABS Module C155. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2886 - Is the resistance less than 5 ohms? Yes If the vehicle is equipped with a 4X4 control module, GO to S13. If the vehicle is not equipped with a 4X4 control module, GO to S14. No CONNECT the negative battery cable. GO to S28. ------------------------------------------------- S13 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE 4X4 CONTROL MODULE DISCONNECTED - Disconnect: 4X4 Control Module C281a. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S14. No CONNECT the negative battery cable. GO to S29. ------------------------------------------------- S14 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE OCSM DISCONNECTED - Disconnect: OCSM C3159. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes If the vehicle is equipped with an APIM, GO to S15. If the vehicle is not equipped with an APIM, GO to S16. No CONNECT the negative battery cable. GO to S30. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2887 ------------------------------------------------- S15 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE APIM DISCONNECTED - Disconnect: APIM C3342. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes GO to S16. No CONNECT the negative battery cable. GO to S31. ------------------------------------------------- S16 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE RCM DISCONNECTED - Disconnect: RCM C310b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes If the vehicle is equipped with a Transmission Control Module (TCM), GO to S17. If the vehicle is not equipped with a TCM, GO to S18. No CONNECT the negative battery cable. GO to S32. ------------------------------------------------- S17 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE TCM DISCONNECTED - Disconnect: TCM C1575. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2888 GO to S18. No CONNECT the negative battery cable. GO to S33. ------------------------------------------------- S18 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TOGETHER WITH THE IC DISCONNECTED - Disconnect: IC C220. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. - Is the resistance less than 5 ohms? Yes REPAIR the circuits. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. No CONNECT the negative battery cable. GO to S34. ------------------------------------------------- S19 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE PCM DISCONNECTED - Disconnect: PCM C175b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S27. No GO to S20. ------------------------------------------------- S20 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE ABS MODULE DISCONNECTED - Disconnect: ABS C155. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2889 Yes CONNECT the negative battery cable. GO to S28. No If the vehicle is equipped with a 4X4 control module, GO to S21. If the vehicle is not equipped with a 4X4 control module, GO to S22. ------------------------------------------------- S21 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE 4X4 CONTROL MODULE DISCONNECTED - Disconnect: 4X4 Control Module C281a. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S29. No GO to S22. ------------------------------------------------- S22 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE OCSM DISCONNECTED - Disconnect: OCSM C3159. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S30. No If the vehicle is equipped with an APIM, GO to S23. If the vehicle is not equipped with an APIM, GO to S24. ------------------------------------------------- S23 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE APIM DISCONNECTED - Disconnect: APIM C3342. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2890 - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S31. No GO to S24. ------------------------------------------------- S24 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE RCM DISCONNECTED - Disconnect: RCM C310b. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S32. No If the vehicle is equipped with a Transmission Control Module (TCM), GO to S25. If the vehicle is not equipped with a TCM, GO to S26. ------------------------------------------------- S25 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE TCM DISCONNECTED - Disconnect: TCM C1575. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S33. No GO to S26. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2891 S26 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND WITH THE IC DISCONNECTED - Disconnect: IC C220. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to S34. No REPAIR the circuit in question. CONNECT all modules. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S27 CHECK FOR CORRECT PCM OPERATION - Disconnect all the PCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the PCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PCM. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S28 CHECK FOR CORRECT ABS MODULE OPERATION - Disconnect the ABS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the ABS module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ABS module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2892 S29 CHECK FOR CORRECT 4X4 CONTROL MODULE OPERATION - Disconnect the 4X4 control module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the 4X4 control module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new 4X4 control module. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S30 CHECK FOR CORRECT OCSM OPERATION - Disconnect the OCSM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the OCSM connector and make sure it seats correctly. - Verify the concern is still present. Is the concern still present? Yes INSTALL a new OCSM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S31 CHECK FOR CORRECT APIM OPERATION - Disconnect the APIM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the APIM connector and make sure it seats correctly. - Verify the concern is still present. - Is the concern still present? Yes INSTALL a new APIM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S32 CHECK FOR CORRECT RCM OPERATION Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2893 - Disconnect all the RCM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the RCM connectors and make sure they seat correctly. - Verify the concern is still present. - Is the concern still present? Yes INSTALL a new RCM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. REPEAT the network test with the scan tool. ------------------------------------------------- S33 CHECK FOR CORRECT TCM OPERATION - Disconnect the TCM connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the TCM connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new TCM. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- S34 CHECK FOR CORRECT IC OPERATION - Disconnect the IC connector. - Check for: - corrosion - damaged pins - pushed-out pins - Connect the IC connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new IC. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------Pinpoint Test T: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Respond Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2894 Communications Network Pinpoint Tests Pinpoint Test T: Intermittent No High Speed Controller Area Network (HS-CAN) Communication, One Or More Modules Are Not Responding During Network Test Normal Operation An open circuit VDB04 (WH/BU) (HS-CAN +) or VDB05 (WH) (HS-CAN -) may cause intermittent or unreliable communication to all modules on the HS-CAN. The HS-CAN is used for communication between the following modules: - 4X4 control module (if equipped) - ABS module - Accessory Protocol Interface Module (APIM) (if equipped) - Instrument Cluster (IC) - Occupant Classification System Module (OCSM) - PCM - Restraints Control Module (RCM) - Transmission Control Module (TCM) (6R60 transmission only) In the event that one of the 2 network circuits (HS-CAN + or HS-CAN -) becomes open to a module on the network, unreliable network communication to all modules on the network may result. This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors PINPOINT TEST T: INTERMITTENT NO HS-CAN COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING NETWORK TEST NOTE: Various modules will set network DTCs during this test procedure. Clear DTCs from all modules after the diagnostic procedure is completed. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- T1 CHECK THE DLC PINS FOR DAMAGE - Ignition OFF. - Disconnect the scan tool cable from the DLC. - Inspect DLC pins 6 and 14 for damage. - Are DLC pins 6 and 14 OK? Yes GO to T2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- T2 CHECK THE HS-CAN TERMINATION RESISTANCE - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and the DLC C251-14, circuit VDB05 (WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2895 - Is the resistance between 54 and 66 ohms? Yes GO to T3. No CONNECT the negative battery cable. Go To Pinpoint Test R. See: Pinpoint Test R: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Respo ------------------------------------------------- T3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO GROUND - Measure the resistance between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. - Are the resistances greater than 1,000 ohms? Yes CONNECT the negative battery cable. GO to T4. No CONNECT the negative battery cable. Go To Pinpoint Test R. See: Pinpoint Test R: Intermittent No Medium Speed Controller Area Network (MS-CAN) Communication, One Or More Modules Are Not Respo ------------------------------------------------- T4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS FOR A SHORT TO VOLTAGE - Ignition ON. - Measure the voltage between the DLC C251-6, circuit VDB04 (WH/BU), harness side and ground; and between the DLC C251-14, circuit VDB05 (WH), harness side and ground. Are the voltages greater than 6 volts? Yes REPAIR the circuit in question. CLEAR the DTCs. REPEAT the network test with the scan tool. No GO to T5. ------------------------------------------------- T5 CHECK FOR RESTORED COMMUNICATION WITH THE PCM DISABLED Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2896 NOTE: A scan tool session must be established prior to disabling the PCM in this test step. If the PCM has failed communication during multiple attempts to identify the vehicle, first identify the vehicle manually by entering a PCM part number, calibration number or tear tag when prompted by the IDS. NOTE: When a vehicle is manually identified by a PCM part number, calibration number or tear tag, the IDS will not automatically run a network test. The network test must be manually selected and run. - Disconnect: BJB Fuse 24 (10A) and 39 (15A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test A. See: Pinpoint Test A: The PCM Does Not Respond To The Scan Tool No INSTALL the removed fuses. GO to T6. ------------------------------------------------- T6 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE ABS MODULE AND 4X4 CONTROL MODULE (IF EQUIPPED) DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB fuse 18 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. If the vehicle is equipped with a 4X4 control module, GO to T7. If the vehicle is not equipped with a 4X4 control module, Go To Pinpoint Test C. See: Pinpoint Test C: The ABS Module Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to T8. ------------------------------------------------- T7 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE ABS MODULE DISCONNECTED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: ABS Module C155. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes CONNECT the ABS module. Go To Pinpoint Test C. See: Pinpoint Test C: The ABS Module Does Not Respond To The Scan Tool No CONNECT the ABS module. Go To Pinpoint Test E. See: Pinpoint Test E: The 4X4 Control Module Does Not Respond To The Scan Tool ------------------------------------------------- T8 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE RCM AND OCSM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2897 - Disconnect: SJB Fuse 17 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. GO to T9. No INSTALL the removed fuse. GO to T10. ------------------------------------------------- T9 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE RCM DISCONNECTED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: RCM C310b. - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes CONNECT the RCM. Go To Pinpoint Test D. See: Pinpoint Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool No CONNECT the RCM. Go To Pinpoint Test F. See: Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool ------------------------------------------------- T10 VERIFY VEHICLE EQUIPMENT - TCM - A TCM is present in 6R60 transmission equipped vehicles only. Inspect the vehicle for a 6R60 transmission. - Is the vehicle equipped with a 6R60 transmission? Yes GO to T11. No GO to T12. ------------------------------------------------- T11 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE TCM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: BJB Fuse 27 (20A) and SJB Fuse 9 (2A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test B. See: Pinpoint Test B: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2898 INSTALL the removed fuses. GO to T12. ------------------------------------------------- T12 VERIFY VEHICLE EQUIPMENT - APIM - Inspect the vehicle for an APIM. - Is the vehicle equipped with an APIM? Yes GO to T13. No GO to T14. ------------------------------------------------- T13 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE APIM DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: BJB Fuse 41 (15A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuse. Go To Pinpoint Test P. See: Pinpoint Test P: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool No INSTALL the removed fuse. GO to T14. ------------------------------------------------- T14 CHECK FOR RESTORED NETWORK COMMUNICATION WITH THE IC DISABLED NOTE: When re-running the network test, the network test application must be first closed or the screen display will revert back to the prior run network test results. - Disconnect: SJB Fuses 8 (15A) and 24 (10A). - Enter the following diagnostic mode on the scan tool: Network Test. - Repeat the network test. - Do all other modules pass the network test? Yes INSTALL the removed fuses. Go To Pinpoint Test G. See: Pinpoint Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool No INSTALL the removed fuses. An intermittent fault is not present. Go To Pinpoint Test S. See: Pinpoint Test S: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding ------------------------------------------------Pinpoint Test U: No Power To The Scan Tool Communications Network Pinpoint Tests Pinpoint Test U: No Power To The Scan Tool Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2899 Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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). Voltage for the scan tool is provided by circuit SBP04 (GN/RD). Ground is provided by circuits GD108 (BK/VT) and GD138 (BK/WH). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - DLC - Scan tool PINPOINT TEST U: NO POWER TO THE SCAN TOOL NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic Overview/Communications Network/Inspection And Verification NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- U1 CHECK THE DLC PINS FOR DAMAGE - Disconnect the scan tool cable from the DLC. - Inspect DLC pins 4, 5 and 16 for damage. - Are DLC pins 4, 5 and 16 OK? Yes GO to U2. No REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool. ------------------------------------------------- U2 CHECK THE DLC VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Measure the voltage between the DLC C251-16, circuit SBP04 (GN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to U3. No VERIFY the Smart Junction Box (SJB) fuse 4 (10A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2900 possible causes of the circuit short. REPEAT the network test with the scan tool. ------------------------------------------------- U3 CHECK THE DLC GROUND CIRCUITS FOR AN OPEN - Disconnect: Negative Battery Cable. - Measure the resistance between the DLC C251-5, circuit GD138 (BK/WH), harness side and ground; and between the DLC C251-4, circuit GD138 (BK/WH), harness side and ground. - Are the resistances less than 5 ohms? Yes REPAIR the scan tool. CONNECT the negative battery cable. REPEAT the network test with the scan tool. No REPAIR the circuit in question. CONNECT the negative battery cable. REPEAT the network test with the scan tool. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2901 Information Bus: Programming and Relearning Programmable Module Installation (PMI) 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. Accessory Protocol Interface Module (APIM) Programming Accessory Protocol Interface Module (APIM) Programming Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2902 Accessory Protocol Interface Module (APIM) Programming Using the Integrated Diagnostic System (IDS) NOTE: If a new Accessory Protocol Interface Module (APIM) is being installed, install the new APIM before carrying out the following procedure. 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current APIM Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. NOTE: Do not disconnect the Vehicle Communication Module (VCM) or USB cables during APIM programming. Select the desired software level from the list of available software for programming then select the "Program APIM" button to begin the APIM programming process. Enter the APIM As-Built data if prompted. - When the VIP is programmed, the CIP will be programmed automatically. 9. The Sync/APIM application downloads the software into the APIM and displays "Programming has been completed successfully". 10. Test the audio system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 2903 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2907 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2908 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2909 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2910 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2914 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2915 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The 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 four 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 three 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/No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index. - 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 ignition in the RUN position (engine not running) if DTC P1000 is set. CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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. Typical Manifold Absolute Pressure (MAP) Sensor Typical Manifold Absolute Pressure (MAP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Control Components Engine Oil Temperature (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. Typical Thread Type Sensor Typical EOT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2929 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2930 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2931 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2932 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2933 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2934 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2935 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2936 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor (HO2S) #11 > Page 2937 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2940 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2941 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S) #22 > Page 2942 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Engine Control Components 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. Typical Heated Oxygen Sensor (HO2S) Typical Heated Oxygen Sensor (HO2S) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) > Page 2945 Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S) Engine Control Components Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2948 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the HO2S electrical connector. 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. Installation 1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the HO2S electrical connector. 4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2949 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the CMS electrical connector. 4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. Installation 1. Apply a light coat of anti-seize lubricant to the threads of the CMS. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the CMS electrical connector. 4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2953 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 EPC pressure during increased engine load, for example during parking maneuvers. Typical Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 2956 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Engine Control Components 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 EPC pressure during increased engine load, for example, during parking maneuvers. Typical Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View > Page 2962 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. 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), which delivers 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 torque-based 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 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: - The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2 wires). - There are two designs: parallel and in-line. 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-line design has a separate motor housing. - An internal spring is used in both designs to return the throttle plate to a default position. The default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. - The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. - 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. - There is one reference voltage and one signal return circuit between the PCM and the ETB. The reference voltage and the signal return circuits are shared with the reference voltage and signal return circuits used by the accelerator pedal position (APP) sensor. There are also two throttle position (TP) signal circuits for redundancy. The redundant TP 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). The TP2 signal reaches a limit of approximately 4.5 volts at approximately 45 degrees of throttle angle. Accelerator Pedal Position (APP) Sensor Depending on the application either a 2-track or 3-track APP sensor is used. For additional information on the APP sensor, refer to Engine Control Components See: Description and Operation/Engine Control Components. Electronic Throttle Control (ETC) System Strategy 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) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2967 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 two processors within the PCM: the main powertrain control processor unit (CPU) and a separate monitoring 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, appropriate corrective action is taken. ETC System With A 3-Track APP Sensor Failure Mode And Effects Management: a - ETC illuminates or displays a message on the message center immediately; MIL illuminates after 2 driving cycles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2968 ETC System With A 2-Track APP Sensor Failure Mode And Effects Management: Electronic Throttle Monitor Operation: a - Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. APP and TP Sensor Inputs Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 2969 Accelerator Pedal Position (APP) Sensor Check: Correlation and range/performance - sensor disagreement between processors internal to the PCM. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Throttle Position (TP) Sensor Check: a - Correlation and range/performance - sensor disagreement between processors internal to the PCM, TP inconsistent with requested throttle plate position. Monitor execution is continuous. Monitor false detection duration is less than 1 second to register a concern. Refer to Diagnostic Trouble Code (DTC) Charts and Descriptions for additional DTC information. Electronic Throttle Actuator Control (TAC) Output Electronic TAC Operation Check: a - Note: For all DTCs, in addition to the MIL, the powertrain malfunction indicator (wrench) is on for the concern that caused the FMEM action. Monitor execution is continuous. Monitor false detection duration is less than 5 seconds to register a concern. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2978 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2979 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2985 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 2986 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2987 Engine Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2988 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2989 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2990 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2991 Engine Control Module: Diagrams C175B Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2992 C175B Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2993 C175E Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2994 C175E Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2995 C175E Part 3 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2996 C175T Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2997 C175T Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Description The EEPROM is contained in an integrated circuit 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 DTC 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. On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction should be learned after a PCM replacement in order to activate the misfire monitor. This can be accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool. 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. Neutral Profile Correction In order for the misfire detection system to function properly, any mechanical inaccuracies in the crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is reset. Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should also be relearned any time the CKP sensor is replaced or major engine repairs have been completed. To determine if the neutral profile learning has been completed, check the MP_LRN parameter identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any misfire DTCs. Programming the VID Block for a Replacement PCM The VID block on a replacement PCM is blank and requires programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM, and the second is manual data entry into the new PCM. Automatic data transfer 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 be downloaded to the new PCM after it has been installed. Carry out manual data entry if the old PCM 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 programmed PCM 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3000 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3001 Engine Control Module: Removal and Replacement Powertrain Control Module (PCM) A/C Tube Brackets PCM Removal All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3002 1. NOTE: PCM installation DOES NOT require new keys. Retrieve the module configuration. Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning Vehicles equipped with a 4.6L (3V) engine 2. Remove the Air Cleaner (ACL). All vehicles 3. Disconnect the RH front wheel speed sensor electrical connector. Remove the nut(s) and position the A/C tube bracket(s) and wiring harness aside. 4. Disconnect the PCM connectors. 5. Remove the 2 bolts and the PCM. Installation All vehicles 1. Install the PCM and the 2 bolts. - Tighten to 10 Nm (89 lb-in). 2. Connect the PCM electrical connectors. 3. Position the wiring harness and the A/C tube bracket(s) and install the nut(s). 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 ACL. All vehicles 5. Restore the module configuration. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. See: Information Bus/Testing and Inspection/Programming and Relearning 6. Reprogram the Passive Anti-Theft System (PATS). Carry out the Parameter Reset procedure. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Passive Anti-Theft System (PATS) Parameter Reset Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 3006 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3007 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3012 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3013 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3017 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3018 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3019 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3020 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 3021 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3026 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3027 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3030 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3031 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3032 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3033 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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. Typical Clutch Pedal Position (CPP) Switch Typical Clutch Pedal Position (CPP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3040 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3041 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Control Components Engine Coolant Temperature (ECT) Sensor The ECT 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 ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel control and for cooling fan control. There are three types of ECT sensors, threaded, push-in, and twist-lock. The ECT sensor is located in an engine coolant passage. Typical Thread Type Sensor Typical Thread Type ECT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3042 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature (ECT) Sensor - 4.0L SOHC Removal and Installation 1. Drain the cooling system. 2. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 3. Remove the clip and the ECT sensor. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3046 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3047 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3048 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3049 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3050 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3054 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 3055 Engine Temperature Sensor: Description and Operation Engine Control Components Cylinder Head Temperature (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. For additional information, refer to Powertrain Control Software See: Description and Operation/Powertrain Control Software for Fail-Safe Cooling Strategy. Typical CHT Sensor Typical CHT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation Fuel Level Sensor: Description and Operation Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3061 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3062 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3063 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3064 Fuel Level Sensor: Service and Repair Fuel Level Sender Fuel Level Sender Removal WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Fuel Pump (FP). For additional information, refer to Fuel Pump See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. 2. Remove the screw and the fuel level sender cover. 3. NOTE: Note the routing of the fuel level sender wire for installation. Remove the heat shrink tube covering the fuel level sender wire electrical connector. 4. Disconnect the fuel level sender wire electrical connector. 5. NOTE: Note the routing of the fuel level sender ground wire for installation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3065 Disconnect the ground wire and remove the screw and lift up to remove the fuel level sender. Installation 1. Route the fuel level sender ground wire along the FP body. 2. Route the fuel level sender wire through the center of the FP. 3. NOTE: Both fuel gauge sending wires must be routed behind the metal sending unit plate. Hook the fuel level sender on the FP and install and tighten the screw. Connect the fuel level sender unit ground wire. 4. Slide the heat shrink tube onto the wire harness and connect the fuel level sender wire electrical connector. 5. WARNING: Do not use an open flame to shrink the heat shrink tube. Use a heat gun only. Fuel residue may be ignited if an open flame is used. Failure to follow this instruction may result in serious personal injury. Using a heat gun, shrink the heat shrink tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3066 6. Install the fuel level sender cover and screw and tighten the screw. 7. Install the FP. For additional information, refer to Fuel Pump See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair/Fuel Pump. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3070 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3071 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3072 Fuel Tank Pressure Sensor: Description and Operation Engine Control Components Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure. Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor In-line Fuel Tank Pressure (FTP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3073 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Removal and Installation WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Evaporative Emission (EVAP) canister. For additional information, refer to Evaporative Emission Canister See: Emission Control Systems/Evaporative Emissions System/Evaporative Emission Control Canister/Service and Repair. 2. Remove the fuel tank shield from the fuel tank. 3. Disconnect the Fuel Tank Pressure (FTP) sensor electrical connector. 4. Disconnect the 3 FTP sensor and vapor tube assembly quick connect couplings from the Fuel Pump (FP) module and the vapor vent valves. 5. Remove the FTP sensor and vapor tube assembly. 6. To install, reverse the removal procedure. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Emission Control Systems/Evaporative Emissions System/Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3077 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3078 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3079 Intake Air Temperature Sensor: Description and Operation Engine Control Components Intake Air Temperature (IAT) 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 sensor 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. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two 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 two IAT sensors. Both sensors are thermistor type devices and operate as described above. 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. Typical Stand-Alone/Non-Integrated Intake Air Temperature (IAT) Sensors 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 Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into a Drop-in or Flange-type MAF sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3083 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3084 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3085 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3086 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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. Typical Manifold Absolute Pressure (MAP) Sensor Typical Manifold Absolute Pressure (MAP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation Oil Temperature Sensor For ECM: Description and Operation Engine Control Components Engine Oil Temperature (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. Typical Thread Type Sensor Typical EOT Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #11 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3097 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3098 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #12 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3099 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3100 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #21 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3101 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3102 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3103 Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) #22 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3104 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3105 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3108 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3109 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3110 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Engine Control Components 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. Typical Heated Oxygen Sensor (HO2S) Typical Heated Oxygen Sensor (HO2S) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) > Page 3113 Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S) Engine Control Components Universal Heated Oxygen Sensor (HO2S) The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio. The measured air/fuel ratio is actually the output from the current controller in the PCM and not a signal that comes directly from the sensor. The universal HO2S also uses a self-contained reference chamber to make sure an oxygen differential is always present. The oxygen for the reference chamber is supplied by pumping small amounts of oxygen ions from the measurement chamber into the reference chamber. The universal HO2S does not need access to outside air. Part to part variance is compensated for by placing a resistor in the connector. This resistor is used to trim the current measured by the current controller in the PCM. Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to enter closed loop operation sooner. The heating element heats the sensor to a temperature of 780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on and off by providing the ground to maintain the sensor at the correct temperature for maximum accuracy. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor Exploded View Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View > Page 3116 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) Heated Oxygen Sensor (HO2S) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Heated Oxygen Sensor (HO2S) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the HO2S electrical connector. 4. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S. Installation 1. Apply a light coat of nickel anti-seize lubricant to the threads of the HO2S. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the HO2S electrical connector. 4. If the RH HO2S is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) and Catalyst Monitor Sensor - Exploded View > Page 3117 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor Catalyst Monitor Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If the RH Catalyst Monitor Sensor (CMS) is being serviced, remove the 2 bolts and position the heat shield aside. 3. Disconnect the CMS electrical connector. 4. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to ease removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS. Installation 1. Apply a light coat of anti-seize lubricant to the threads of the CMS. 2. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS. - Calculate the correct torque wrench setting for the following torque. - Using the Exhaust Gas Oxygen Sensor Socket, tighten to 41 Nm (30 lb-ft). 3. Connect the CMS electrical connector. 4. If the RH CMS is being serviced, position the heat shield and install the 2 bolts. - Tighten to 20 Nm (177 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 3121 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 EPC pressure during increased engine load, for example during parking maneuvers. Typical Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3124 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Engine Control Components 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 EPC pressure during increased engine load, for example, during parking maneuvers. Typical Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 3130 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3134 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3135 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor > Page 3138 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3139 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3140 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3141 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3145 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3146 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3147 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3148 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3149 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3150 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3151 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3152 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3153 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) 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 3158 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) Engine Control Components 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 speed, 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. Typical Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3162 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3163 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor > Page 3166 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3167 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3168 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3169 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3173 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3174 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3175 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3176 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3177 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3178 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3179 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3180 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3181 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation Variable Valve Timing Actuator: Description and Operation Variable Camshaft Timing (VCT) System Overview The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are four 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 four 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. The VCT system knocking and noise concerns are diagnosed in the Testing and Inspection section. For additional information, refer to the Engine System - General Information. Verification of incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are primary possible causes. Verify correct oil pressure and flow, refer to the Engine System - General Information. Variable Camshaft Timing (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 indicates the CMP signal for that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT), engine coolant temperature (ECT), engine oil temperature (EOT), CMP, throttle position (TP), mass air flow (MAF), and CKP sensors 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Page 3185 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. 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 two 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. VCT System Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Locations > VCT Solenoid 1 > Page 3190 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > VCT Solenoid 1 > Page 3193 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams > Page 3194 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 Variable Camshaft Timing (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 (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 3199 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) Engine Control Components 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 speed, 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. Typical Vehicle Speed Sensor (VSS) Typical Vehicle Speed Sensor (VSS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Description and Operation Air Diverter Solenoid: Description and Operation Engine Control Components Secondary Air Injection (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. Secondary AIR Bypass Solenoid Secondary AIR Bypass Solenoid Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation Engine Control Components 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. Secondary AIR Diverter Valve Secondary AIR Diverter Valve Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump > Component Information > Description and Operation Air Injection Pump: Description and Operation Engine Control Components 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 mass air flow/intake air temperature sensor. For additional information on the secondary AIR injection system, refer to Secondary Air Injection (AIR) System See: Description and Operation. Secondary Air Pump Secondary Air Pump Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 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 (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 powertrain control module (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/Catalyst Efficiency Monitor. For most vehicles, only two 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 (PZEVs) use three HO2Ss. The stream 1 sensor (HO2S11) located before the catalyst is used for primary fuel control, the stream 2 sensor (HO2S12) is used to monitor the light-off catalyst, and the stream 3 sensor (HO2S13) located after the catalyst is used for long term fuel trim control to optimize catalyst efficiency (fore aft oxygen sensor control). V-Engines V-Engines In-Line Engines In-Line Engines Catalytic Converter 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 three way catalytic converter (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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3214 catalyst. Three Way Catalytic Converter (TWC) Conversion Efficiency A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window 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. TWC Conversion Efficiency Chart TWC Conversion Efficiency Chart Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. 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 three HO2Ss 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. Typical Bank 1 Catalyst 2 H2OS Configuration Typical Bank 1 Catalyst 2 HO2S Configuration Typical Bank 1 Catalyst 3 H2OS Configuration Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3215 Typical Bank 1 Catalyst 3 HO2S Configuration Underbody Catalyst The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line with the light off catalyst, or the underbody catalyst may be common to two light off catalysts, forming a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific vehicle, refer to the Exhaust System for the exhaust system exploded view. Three Way Catalytic (TWC) Converter The TWC contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC 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 PCM with information related to the oxygen content of the exhaust gas. For additional information on the HO2S, refer to Engine Control Components See: Computers and Control Systems/Description and Operation/Engine Control Components. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3216 Catalytic Converter: Service and Repair Exhaust System - Exploded View 4.0L Explorer Sport Trac NOTE: Vehicle body removed for clarity. 4.6L Explorer Sport Trac NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3217 4.0L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3218 4.6L Explorer/Mountaineer NOTE: Vehicle body removed for clarity. NOTE: Premier exhaust shown, standard exhaust similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3219 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3224 Canister Purge Control Valve: Description and Operation Engine Control Components Evaporative Emission (EVAP) Canister Purge Valve 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. For E-Series, Escape/Mariner, Expedition, F-Series, and Navigator, the PCM outputs a duty cycle between 0% and 100% to control the EVAP canister purge valve. For all others, the PCM outputs a variable current between 0 mA and 1,000 mA to control the EVAP canister purge valve. Typical EVAP Canister Purge Valve Typical EVAP Canister Purge Valve (Part 1) Typical EVAP Canister Purge Valve (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Diagrams > Page 3225 Canister Purge Control Valve: Service and Repair Evaporative Emission Canister Purge Valve Removal and Installation WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious 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. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious 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. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Service and Repair Canister Vent Valve: Service and Repair Fuel Vapor Vent Valve Removal and Installation WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious 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. - Carry out the Evaporative Emission System Leak Test. For additional information, refer to Evaporative Emission System Leak Test See: Testing and Inspection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Solenoid, Evaporative System > Component Information > Description and Operation Leak Detection Solenoid: Description and Operation Engine Control Components 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. Typical Canister Vent (CV) Solenoid Typical Canister Vent (CV) Solenoid Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations Leak Detection Valve: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3239 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Valve, Evaporative System > Component Information > Locations > Page 3240 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations > Page 3245 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View EGR Control Solenoid: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components Exploded View > Page 3250 EGR Control Solenoid: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid 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. EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid Duty Cycle Graph EGR Vacuum Regulator Solenoid Data Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Description and Operation EGR Tube: Description and Operation Engine Control Components Exhaust Gas Recirculation (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 two pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the differential pressure feedback EGR sensor which provides feedback to the PCM. EGR Orifice Tube Assembly EGR Orifice Tube Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 3259 EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) System Module Tube Exhaust Gas Recirculation (EGR) System Module Tube - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 2. Disconnect the EGR system module-to-exhaust manifold tube lower fitting and remove the tube. - To install, tighten to 40 Nm (30 lb-ft). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Electric Exhaust Gas Recirculation (EEGR) Valve 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). EEGR Motor/Valve Assembly EEGR Motor/Valve Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3264 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) System Module (ESM) Engine Control Components Exhaust Gas Recirculation (EGR) System Module (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 ignition on. The system provides the PCM with a differential pressure feedback EGR signal, identical to a traditional differential pressure feedback EGR system. ESM ESM (Part 1) ESM (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3265 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve Engine Control Components Exhaust Gas Recirculation (EGR) Valve The EGR valve in the differential pressure feedback EGR system is a conventional, vacuum-actuated valve. 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. Typical EGR Valve Typical EGR Valve (Part 1) Typical EGR Valve (Part 2) EGR Flow Rate Graph Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 3268 EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 3274 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Diagrams > Page 3279 Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve - 4.0L SOHC Removal and Installation 1. Disconnect the PCV valve electrical connector. 2. Disconnect the PCV valve hose. 3. NOTE: If the PCV valve is removed from the valve cover, a new PCV valve must be installed. Rotate the PCV valve counterclockwise and remove it from the valve cover. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations > Page 3284 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Components - Exploded View Exhaust Gas Recirculation (EGR) System Components - Exploded View, 4.0L SOHC 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) System Components - Exploded View > Page 3291 Pressure Feedback Exhaust Sensor: Service and Repair Exhaust Gas Recirculation (EGR) System Module Exhaust Gas Recirculation (EGR) System Module - 4.0L SOHC Removal and Installation 1. Disconnect the EGR system module electrical and vacuum connectors. 2. Disconnect the EGR system module-to-exhaust manifold tube upper fitting. - To install, tighten to 40 Nm (30 lb-ft). 3. NOTE: When installing the new EGR module gasket, install with the side with the raised circle facing the intake manifold. Remove the 2 bolts, the EGR system module and the gasket. Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 4. NOTE: The EGR system module sealing surfaces are soft metals. Carefully clean the EGR system module sealing surfaces. 5. To install, reverse the removal procedure. - Install a new EGR system module gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... ............................................207-276 kPa (30-40 psi) Engine running.................................................. .................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3296 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to Spring Lock Couplings See: Fuel Line Coupler/Service and Repair/Spring Lock Couplings. 4. NOTE: 4.6L shown, 4.0L similar. Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail. 5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 6. Connect the battery ground cable. 7. 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. 8. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 9. NOTE: 4.6L shown, 4.0L similar. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3297 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious 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. NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Typical Diagnostic Reference Value Measured/PID Values Hot Idle ............................................................................................................ .......................................................................................... 750 - 820 RPM Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Accelerator Pedal - Fixed > Page 3308 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3312 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3313 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View Air Filter Element: Service and Repair Intake Air System Components - Exploded View Intake Air System Components - Exploded View Coolant Expansion Tank Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3319 Intake Air System Components - 4.6L (3V) 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3320 Air Filter Element: Service and Repair Air Cleaner Element Air Cleaner Element 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 (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Detach the wiring harness retainer from the coolant expansion tank. All vehicles 3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL. 4. Unclip and remove the ACL cover. 5. Remove the ACL element. 6. NOTE: Clean the inside of the ACL tray. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3324 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3325 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3326 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3327 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 3328 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) 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 Engine Control Components 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 there is a concern in the EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly. This is detected by the inability to pull vacuum in the fuel tank after a fueling event. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious 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. NOTE: It may be necessary to reposition the lower end of the door jam weatherstripping 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Resistance ...................................................................................................................... ............................................................. 11 - 18 Ohms Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3340 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Flow and Leakage ...................................................................................... Refer to Pinpoint Test HC12 at Computers and Control Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3343 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3344 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3345 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3346 Fuel Injector: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3347 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3348 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3349 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3350 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 > Page 3351 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3352 Fuel Injector: Description and Operation Engine Control Components Fuel Injectors Note: 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. Install a new fuel injector if the flow is checked and found to be out of specification. Typical Fuel Injector Typical Fuel Injector (Part 1) Typical Fuel Injector (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Rail and Fuel Injector - Exploded View Fuel Injector: Service and Repair Fuel Rail and Fuel Injector - Exploded View Fuel Rail and Fuel Injector - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disconnect - Type I WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. NOTICE: 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Disconnect the safety clip from the fuel tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3359 4. Install the Spring Lock Coupling Disconnect 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. NOTE: 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. 3. Pull on the spring lock coupling to make sure it is fully seated. Install the fuel tube safety clip on the male end. 4. Connect the battery ground cable. Disconnect - Type II WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3360 WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. NOTICE: 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Remove the fuel tube safety clip. 4. Install the Spring Lock Coupling Disconnect Tool. 5. Close and push the Spring Lock Coupling Disconnect Tool into the open side of the cage. 6. Separate the spring lock coupling. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3361 Connect - Type II 1. Inspect and clean both spring lock coupling ends. Install new O-ring seals and garter springs if necessary. 2. NOTE: 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. 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 tube. 4. Install the fuel tube safety clip. 5. Connect the battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3362 Fuel Line Coupler: Service and Repair Quick Connect Coupling Quick Connect Coupling Disconnect - Type I WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. NOTICE: 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Unclip the locking tab. 4. Depress the tabs and press the clip downward. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3363 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. NOTE: 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. 5. Connect the battery ground cable. Disconnect - Type II WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3364 serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. NOTICE: 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 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. 2. NOTE: 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. 3. Connect the battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3365 Disconnect - Type III WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. NOTICE: 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Release the locking tab on the quick connect coupling. 2. 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. NOTE: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3366 3. Position the locking tab into the latched position. Disconnect - Type IV WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage may occur. Always install plugs to any open orifices or tubes. NOTICE: 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 or damage to the tube or connector retaining clip may occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector. NOTE: During the repair or replacement of fuel-related components, all fuel liquid and fuel vapor openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. Compress the clip legs and push the clip into the quick connect coupling. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Spring Lock Couplings > Page 3367 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. NOTE: 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. 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. 4. Connect the battery ground cable. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations Fuel Pressure Sensor/Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3371 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3372 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3373 Fuel Pressure Sensor/Switch: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3374 Fuel Pressure Sensor/Switch: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3375 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure Key ON Engine OFF (KOEO)............................................................................................................... ............................................207-276 kPa (30-40 psi) Engine running.................................................. .................................................................................................................................207-276 kPa (30-40 psi) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3380 Fuel Pressure: Testing and Inspection Fuel System Pressure Test WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release See: Fuel Filter/Fuel Pressure Release/Service and Repair. 2. Disconnect the battery ground cable. 3. Disconnect the fuel supply tube-to-fuel rail spring lock coupling. For additional information, refer to Spring Lock Couplings See: Fuel Line Coupler/Service and Repair/Spring Lock Couplings. 4. NOTE: 4.6L shown, 4.0L similar. Install the Fuel Pressure Test Kit in line between the fuel supply tube and fuel rail. 5. NOTE: The Inertia Fuel Shutoff (IFS) switch electrical connector was disconnected during fuel system pressure release. Connect the IFS switch electrical connector. 6. Connect the battery ground cable. 7. 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. 8. Test the fuel system pressure to make sure it is within the specified range. For additional information, refer to Specifications. 9. NOTE: 4.6L shown, 4.0L similar. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the system. Place the fuel in a suitable container. Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit and relieve the fuel system pressure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3381 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Fuel Pump Driver Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Fuel Pump Driver Module > Page 3386 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3387 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Control Unit > Component Information > Locations > Page 3388 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) - Explorer Sport Trac Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector. 3. Remove the 2 bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3392 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 3393 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail Fuel Rail: Service and Repair Fuel Rail Fuel Rail Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTICE: If used as a leverage device, the fuel rail may be damaged. Care must be taken when working around the fuel rail. NOTE: During the repair or replacement of 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 all caps, tape and other protective materials prior to installation. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the spring lock coupling. 4. Remove the intake manifold. 5. Remove the fuel supply tube bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 6. Disconnect the 6 fuel injector electrical connectors. 7. Disconnect the fuel pressure and temperature sensor electrical and vacuum connectors. 8. Remove the 4 bolts and the fuel rail and injectors as an assembly. - To install, tighten to 23 Nm (17 lb-ft). 9. Remove the fuel injectors. Remove and discard the O-ring seals. 10. NOTICE: O-ring seals are made of special fuel-resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. NOTICE: Do not reuse O-ring seals. The removal and installation process may damage the used O-ring seals, and cause the fuel system to leak. NOTE: Install new fuel injector O-ring seals and lubricate them with clean engine oil. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3398 Fuel Rail: Service and Repair Fuel Rail Supply Tube Fuel Rail Supply Tube Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. NOTE: During the repair or replacement of 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 all caps, tape and other protective materials prior to installation. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail supply tube spring lock coupling. 5. Remove the fuel rail supply tube bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the 4 bolts and the fuel rail supply tube. - To install, tighten to 6 Nm (53 lb-in). 7. NOTICE: O-ring seals are made of special fuel-resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. NOTICE: Do not reuse O-ring seals. The removal and installation process may damage the used O-ring seals, and cause the fuel system to leak. Remove and discard the fuel rail supply tube O-ring seals. 8. To install, reverse the removal procedure. - Lubricate the new O-ring seals with clean engine oil prior to installation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail > Page 3399 Fuel Rail: Service and Repair Fuel Rail and Fuel Injector - Exploded View Fuel Rail and Fuel Injector - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Supply Line: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3404 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3405 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3406 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3407 Fuel Supply Line: Service and Repair Fuel Lines and Fuel Filter - Exploded View Fuel Lines and Fuel Filter - Exploded View Explorer Sport Trac NOTE: 4.6L shown, 4.0L similar. NOTE: Vehicle body removed from art for clarity. Explorer/Mountaineer NOTE: 4.6L shown, 4.0L similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3408 NOTE: Vehicle body removed from art for clarity. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3409 Fuel Supply Line: Service and Repair Fuel Lines Fuel Lines Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. With the vehicle in NEUTRAL, position it on a 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View Fuel Filler Hose: Service and Repair Fuel Tank and Filler Pipe - Exploded View Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3415 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3416 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3417 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3418 Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Fuel Tank Filler Pipe Removal and Installation All vehicles WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury. WARNING: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury. NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation. 1. Drain the fuel tank. 2. NOTE: The fuel tank filler pipe hose between the fuel tank filler pipe and the fuel tank is serviceable separately. The fuel tank filler pipe does not have to be removed from the vehicle to service the fuel tank filler pipe hose. If necessary, loosen the fuel tank filler pipe hose clamp at the fuel tank and disconnect the hose and remove from the vehicle. - To install, tighten to 3 Nm (27 lb-in). Explorer Sport Trac 3. Open the fuel tank filler cap. Explorer/Mountaineer 4. Remove the fuel tank filler pipe upper retainer. 5. NOTE: Body panel and fuel door removed from art 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. Remove the 3 bolts. - To install, tighten to 1 Nm (9 lb-in). 7. Disconnect the fuel filler pipe vapor tube-to-Fuel Tank Pressure (FTP) sensor and vapor tube assembly quick connect coupling. 8. Disconnect the rear axle vent hose. 9. Disconnect the dust separator hose. 10. Remove the 2 bolts and the fuel tank filler pipe assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 3419 - To install, tighten to 15 Nm (133 lb-in). 11. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Engine Control Components 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. Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 3425 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir Engine Control Components 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 ignition 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3426 Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3427 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3428 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation > Page 3429 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation All vehicles WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module Engine Control Components 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. Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 3437 Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module and Reservoir Engine Control Components 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 ignition 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3441 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3442 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3443 Fuel Temperature Sensor: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3444 Fuel Temperature Sensor: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3445 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3452 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3453 Inertia Fuel Shutoff Switch: Description and Operation Engine Control Components Inertia Fuel Shut-off (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone 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, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 3454 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. NOTE: 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 2 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Intake Air System Components - Exploded View Intake Air Duct: Service and Repair Intake Air System Components - Exploded View Intake Air System Components - Exploded View Coolant Expansion Tank Intake Air System Components (4.0L SOHC) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3459 Intake Air System Components - 4.6L (3V) 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Intake Air System Components - Exploded View > Page 3460 Intake Air Duct: Service and Repair Air Cleaner Outlet Pipe Air Cleaner Outlet Pipe Removal and Installation Vehicles equipped with a 4.0L SOHC engine 1. Detach the wiring harness retainer from the Air Cleaner (ACL) outlet pipe. Vehicles equipped with a 4.6L (3V) engine 2. Disconnect the brake booster vacuum hose from the ACL outlet pipe. All vehicles 3. Disconnect the crankcase breather hose from the ACL outlet pipe. 4. Loosen the clamps and remove the ACL outlet pipe. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3464 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3465 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Fuel Pump Driver Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Fuel Pump Driver Module > Page 3471 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3472 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3473 Fuel Pump Control Unit: Service and Repair Fuel Pump Driver Module (FPDM) - Explorer Sport Trac Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Fuel Pump Driver Module (FPDM) electrical connector. 3. Remove the 2 bolts and the FPDM. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 3477 Fuel Pump Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3478 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 3482 Main Relay (Computer/Fuel System): Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3483 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3488 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3489 Accelerator Pedal Position Sensor: Description and Operation Engine Control Components Accelerator Pedal Position (APP) Sensor The APP sensor is an input to the powertrain control module (PCM) and is used to determine the amount of torque requested by the operator. Depending on the application either a 2-track or 3-track APP sensor is used. 2-Track APP Sensor There are two pedal position signals in the sensor. Both signals, APP1 and APP2, have a positive slope (increasing angle, increasing voltage), but are offset and increase at different rates. The two pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other input is used. There are two reference voltage circuits, two signal return circuits, and two signal circuits (a total of six circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position (TP) sensor. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 2-Track APP Sensor Typical 2-Track APP Sensor 3-Track APP Sensor There are three pedal position signals in the sensor. Signal 1, APP1, has a negative slope (increasing angle, decreasing voltage) and signals 2 and 3, 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. The three pedal position signals make sure the PCM receives a correct input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. If a concern is present with one of the circuits the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. There are two reference voltage circuits, two signal return circuits, and three signal circuits (a total of seven circuits and pins) between the PCM and the APP sensor assembly. The reference voltage circuits and the signal return circuits are shared with the reference voltage circuit and signal return circuit used by the electronic throttle body (ETB) throttle position sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. 3-Track APP Sensor Typical 3-Track APP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Air Flow Meter/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3493 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3494 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3495 Air Flow Meter/Sensor: Description and Operation Engine Control Components 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 (TCC) 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 IAT sensor. The hot wire electronic sensing element must be replaced as an assembly. Replacing only the element may change the air flow calibration. Diagram of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire (and IAT Sensor Wire Where Applicable) Terminals 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 Typical Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3496 Typical Drop-in Mass Air Flow (MAF) Sensor Typical Drop-in Mass Air Flow (MAF) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3497 Air Flow Meter/Sensor: Service and Repair Mass Air Flow (MAF) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Mass Air Flow (MAF) sensor electrical connector. 2. Remove the 2 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 (V6-4.0L (2009)) 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 Pressure Sensor/Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3501 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3502 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3503 Fuel Pressure Sensor/Switch: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3504 Fuel Pressure Sensor/Switch: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3505 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations Fuel Temperature Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3509 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3510 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3511 Fuel Temperature Sensor: Description and Operation Engine Control Components 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. Typical Fuel Rail Pressure Temperature (FRPT) Sensor Typical Fuel Rail Pressure Temperature (FRPT) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3512 Fuel Temperature Sensor: Service and Repair Fuel Rail Pressure and Temperature Sensor - 4.0L SOHC Removal and Installation WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors. 5. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 6 Nm (53 lb-in). 6. Remove and discard the O-ring seal. 7. NOTICE: Use an O-ring seal made of special fuel resistant material. Fuel will damage ordinary O-ring seals and may cause the fuel system to leak. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3513 NOTICE: Do not reuse the O-ring seal. The removal and installation process may damage the used O-ring seals and cause the fuel system to leak. To install, reverse the removal procedure. - Lubricate the new O-ring seal with clean engine oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3517 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3518 Inertia Fuel Shutoff Switch: Description and Operation Engine Control Components Inertia Fuel Shut-off (IFS) Switch The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel cone held in place by a magnet. When a sharp impact occurs, the cone 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, Roadside Emergencies for the location of the IFS switch. Typical Inertia Fuel Shut-off (IFS) Switch Typical Inertia Fuel Shut-off (IFS) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3519 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. NOTE: 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 2 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3523 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3524 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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) Throttle Position Sensor > Page 3527 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3528 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3529 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3530 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury. 1. Remove the Air Cleaner (ACL) outlet tube. 2. Disconnect the Throttle Body (TB) electrical connector. 3. Disconnect the Throttle Position (TP) sensor electrical connector. 4. Remove the nut and position the wiring harness bracket aside. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the 4 bolts, the TB and the gasket. Discard the gasket. - To install, tighten to 9 Nm (80 lb-in). 6. To install, reverse the removal procedure. - Install a new TB gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Throttle Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3537 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3538 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Throttle Position Sensor Engine Control Components Electronic Throttle Body (ETB) Throttle Position Sensor The ETB throttle position sensor has 2 signal circuits in the sensor for redundancy. The redundant ETB throttle position signals are required for increased monitoring. The first ETB throttle 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). The 2 ETB throttle 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. The reference voltage circuit and the signal return circuit is shared with the reference voltage circuits and signal return circuits used by the APP sensor. For additional information, refer to Torque Based Electronic Throttle Control (ETC) See: Computers and Control Systems/Electronic Throttle Control Module/Description and Operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic Throttle Body (ETB) Throttle Position Sensor > Page 3541 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor Engine Control Components Throttle Position (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, four operating conditions are determined by the PCM from the TP. These 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 Typical TP Sensor Typical TP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3542 Throttle Position Sensor: Service and Repair Throttle Position (TP) Sensor Removal All vehicles 1. Remove the Air Cleaner (ACL) outlet pipe. 2. Disconnect the Throttle Position (TP) sensor electrical connector. Vehicles equipped with a 4.6L (3V) engine 3. Disconnect the PCV hose from the heated PCV fitting. 4. Disconnect the heated PCV fitting electrical connector. 5. Remove the 2 bolts and the heated PCV fitting. - Remove and discard the heated PCV fitting O-ring seal. All vehicles 6. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB) temperature exceeds 120°C (248°F). NOTE: Do not use power tools. Remove the TP sensor. 1. Using a suitable heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP sensor bolt ear reaches approximately Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3543 55°C (130°F), this should take no more than 3 minutes using a 1100-watt heat gun. The heat gun should be about an 25.4 mm (1 in) away from the ETB. 2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB. 3. Using hand tools, quickly remove the bolt farthest from the heat source first and discard. 4. Using hand tools, remove the remaining bolt and discard. 5. Remove and discard the TP sensor. Installation All vehicles 1. NOTE: Do not use power tools. Install the new TP sensor. - Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in). Vehicles equipped with a 4.6L (3V) engine 2. Install a new O-ring seal and position the heated PCV fitting and install the 2 bolts. 3. Connect the heated PCV fitting electrical connector. 4. Connect the PCV hose to the heated PCV fitting. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3544 All vehicles 5. Connect the TP sensor electrical connector. 6. Install the ACL outlet pipe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Actuator > Component Information > Description and Operation Variable Induction Control Actuator: Description and Operation Engine Control Components 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. Failure to follow these instructions may result in personal injury. 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 a calibrated RPM. The shutter is in the closed position to prevent airflow blend from occurring in the intake manifold. The motorized unit is energized above a calibrated 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications Base ignition timing................................................................................................................10 degrees Before Top Dead Center (BTDC), Non-adjustable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3560 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3561 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3564 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3565 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3566 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3567 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3571 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3572 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3573 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3574 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3575 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair Spark Plug Wires Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Description and Operation in the Description and Operation. Squeeze the locking tabs and twist while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 2. Detach the spark plug wires from the spark plug wire retainers. 3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wires from the spark plugs. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3583 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3584 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3585 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3586 Ignition Coil: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3587 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3588 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3589 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3590 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3591 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Coil On Plug (COP) 1 > Page 3592 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil on Plug (COP) Ignition Coil: Description and Operation Coil on Plug (COP) Engine Control Components 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). For additional information, refer to Ignition Systems See: Description and Operation/Ignition Systems. Typical Coil On Plug (COP) Typical Coil On Plug (COP) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Coil on Plug (COP) > Page 3595 Ignition Coil: Description and Operation Coil Pack Engine Control Components 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 6-tower series 5 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. Typical Four-Tower Coil Pack Typical Four-Tower Coil Pack Typical Six-Tower Coil Pack Typical Six-Tower Coil Pack Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil Ignition Coil: Service and Repair Ignition Coil Ignition Coil Removal and Installation 1. Disconnect the ignition coil electrical connector. 2. Disconnect the radio noise suppressor electrical connector. 3. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. For additional information, refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Description and Operation in the Description and Operation. Squeeze the tabs and twist, while pulling upward to disconnect the 6 spark plug wires from the ignition coil. 4. Remove the 4 bolts and the ignition coil. - To install, tighten to 6 Nm (53 lb-in). 5. NOTE: Apply silicone dielectric compound to the inside of the ignition coil boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil > Page 3598 Ignition Coil: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3602 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3603 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3604 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3605 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3611 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor 1 > Page 3612 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3615 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Camshaft Position Sensor > Page 3616 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3617 Camshaft Position Sensor: Description and Operation Engine Control Components Camshaft Position (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 two CMP sensors are equipped with variable camshaft timing (VCT). The second sensor is used to identify the position of the camshaft on bank 2. There are two types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin Hall-effect type sensor. Typical Variable Reluctance CMP Sensor Typical Variable Reluctance CMP Sensor Typical Hall-effect CMP Sensor Typical Hall-effect CMP Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 3618 Camshaft Position Sensor: Service and Repair Camshaft Position (CMP) Sensor - 4.0L SOHC Removal and Installation 1. Disconnect the Camshaft Position (CMP) sensor electrical connector. 2. Remove the bolt and the CMP sensor. - To install, tighten to 6 Nm (53 lb-in). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3622 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3623 Crankshaft Position Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3624 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3625 Crankshaft Position Sensor: Description and Operation Engine Control Components 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 decelerations between teeth. Typical Crankshaft Position (CKP) Sensor Typical Crankshaft Position (CKP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3626 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor - 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 3. Remove the 2 bolts and the CKP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: Be sure the sensor wiring is routed away from the battery cable. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Lock Cylinder - Functional 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. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys must be programmed. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 3632 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Lock Cylinder - Non Functional Removal 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. 3. Program the new PATS keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3636 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3637 Knock Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3638 Knock Sensor: Description and Operation Engine Control Components 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. Two Types of Knock Sensor (KS) Two Types of Knock Sensor (KS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3639 Knock Sensor: Service and Repair Knock Sensor (KS) - 4.0L SOHC Removal and Installation 1. Remove the intake manifold. 2. Disconnect the Knock Sensor (KS) electrical connector. 3. Remove the bolt and the KS. - To install, tighten to 20 Nm (177 lb-in). 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Gap Item....................................................................................................................................................... ...............................................................Specification Spark Plug Gap.................................................................................................................................... ....................................1.32-1.42 mm (0.052-0.056 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 3644 Spark Plug: Specifications Torque Specifications Spark plugs........................................................................................................................................... ........................................................17 Nm (150 lb-in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3645 Spark Plug: Application and ID Item....................................................................................................................................................... ...............................................................Specification Spark Plug type.................................................................................................................................... ....................................................................AGSF24N Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3646 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. - Install a new 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. Install new spark plugs. 4. Inspect for normal burning. - Check for light tan or gray deposits on the firing tip. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3647 6. Inspect for overheating, identified by white or light gray spots and a 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. - Install new spark plugs. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View Spark Plug: Service and Repair Engine Ignition Components - Exploded View Engine Ignition Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 3650 Spark Plug: Service and Repair Spark Plugs Spark Plugs Removal and Installation 1. NOTICE: It is important to twist the spark plug wire boot while pulling upward to avoid possible damage to the spark plug wire. NOTE: Spark plug wires must be connected to the correct spark plug. Refer to the Cylinder-to-Coil Terminal Relationship, Engine Ignition See: Description and Operation in the Description and Operation. With a twisting motion, use the Spark Plug Wire Remover to pull the spark plug wire from the spark plug. 2. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs. Remove the spark plugs. - To install, tighten to 17 Nm (150 lb-in). 3. Use a suitable spark plug gap tool to check and adjust the spark plug gap. 4. NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal 1. Remove the front floor console. 2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector. 3. Remove the screw and the BSIA. Installation 1. Install the BSIA and the screw. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3657 2. Connect the BSIA electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. With the ignition ON, press the 4X4 HIGH button on the Mode Select Switch (MSS). 3. Remove the 3 heat shield bolts and the heat shield. - To install, tighten to 16 Nm (142 lb-in). 4. Disconnect the transfer case shift motor electrical connector. 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 3662 7. To install, reverse the removal procedure. - Apply a coat of multi-purpose grease to the transfer case shift motor bolts. - Apply a thin coat of silicone sealant to the shift motor mating surface. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3678 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3679 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3685 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3686 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3691 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > 4X4 Control Module > Page 3694 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > 4X4 Control Module > Page 3695 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > Page 3696 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 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 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Mode Switch: Description and Operation Engine Control Components 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. Typical Transmission Control Switch (TCS) (Column Shift) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) (Floor Shift) Typical Transmission Control Switch (TCS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Service and Repair > Transmission Control Switch (TCS) Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS) External Controls Transmission Control Switch (TCS) The Transmission Control Switch (TCS) is a momentary contact switch located on the selector lever knob. Pushing the TCS will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on the Instrument Cluster (IC). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Service and Repair > Transmission Control Switch (TCS) > Page 3707 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. 2. Remove the Transmission Control Switch (TCS) from the knob. Installation 1. Install the TCS into the selector lever knob. 2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3711 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3712 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3713 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3714 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3715 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3716 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3717 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3718 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3719 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3724 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3725 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3726 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 3729 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 3730 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor 5R55S Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3733 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Turbine Shaft Speed (TSS) sensor connector. 8. Remove the TSS sensor. 1. Remove the TSS sensor screw. 2. Remove the TSS sensor from the transmission. - Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3734 Installation All vehicles 1. Inspect the TSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the TSS sensor into the transmission. 2. Tighten the TSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the TSS sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever bracket and selector lever bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3735 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3736 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor 5R55S Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3737 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Heated Oxygen Sensor (HO2S) connector from the transmission case. 8. Disconnect the Output Shaft Speed (OSS) sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3738 9. Remove the OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the OSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the OSS sensor into the transmission. 2. Tighten the OSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the OSS sensor connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3739 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3740 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3741 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor 5R55S Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3742 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor connector. 8. Remove the intermediate shaft speed sensor. 1. Remove the intermediate shaft speed sensor screw. 2. Remove the intermediate shaft speed sensor from the transmission. - Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3743 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the intermediate shaft speed sensor into the transmission. 2. Tighten the intermediate shaft speed sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the intermediate shaft speed sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3744 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3749 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3750 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 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. 6. Disconnect the electrical connector(s). 7. Disengage the locking tangs and remove the Mode Select Switch (MSS) from the instrument panel center finish panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3751 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3760 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3761 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3767 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3768 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3773 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3774 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3775 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3776 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3777 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming PROM - Programmable Read Only Memory: All Technical Service Bulletins Computers/Controls Sync Software Programming TSB 08-21-2 10/27/08 SYNC SOFTWARE PROGRAMMING SERVICE TIPS FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus 2009 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator 2009 Mark LT MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE The Sync Accessory Protocol Interface Module (APIM) may require updates to add system enhancements, improve system reliability or address consumer issues. The installation or availability of these updates may be made available in two different methods: ^ Downloadable consumer Service Pack updates available through www.SYNCmyride.com website. ^ APIM Programming Using the Integrated Diagnostic System (IDS). The tool and installation requirements vary between these two methods. This information is being provided to supplement current publications, clarify the requirements needed to reprogram or update the APIM module and provide some additional diagnostic/operational system information. ACTION Refer to the Service Tips for details. SERVICE TIPS Downloadable Consumer Service Pack Updates (Available At www.SyncMyRide.com) These Service Pack Updates are for the Consumer Interface Processor (CIP) side of the APIM module only and are customized for each vehicle based on the last reported APIM software level state. The software download process will bundle the appropriate service packs that are required to achieve the desired state. This is why consumers are asked to report back to the website once they have completed the install. NOTE IT IS NOT RECOMMENDED TO REUSE A DOWNLOADED SERVICE PACK ACROSS MULTIPLE VEHICLES. EACH DOWNLOAD IS PACKAGED ACCORDINGLY TO THE CURRENT STATE OF THE VEHICLE THAT THE DOWNLOAD IS INTENDED FOR. NOTE CONSUMERS DO NOT HAVE THE ABILITY TO REMOVE SERVICE PACK UPDATES ONCE THEY ARE INSTALLED. Steps For Consumer's To Update Sync With The Latest Enhancements 1. Prepare universal serial bus (USB) storage drive by: a. Log into their Sync account and select applications and updates to download. b. Locates a portable USB storage drive that they can take to their vehicle. NOTE FOR OWNERS OF MULTIPLE SYNC-EQUIPPED VEHICLES, IT IS STRONGLY RECOMMENDED TO USE A SEPARATE USB DRIVE FOR EACH SYNC-EQUIPPED VEHICLE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3783 Dedicating a USB drive to each vehicle's Sync system helps keep each vehicle's download and installation history current and accurate. In addition, as new Sync features and functionalities become available, consumers may decide to install different features on different vehicles. Dedicated USB drives will help maintain the unique applications for each vehicle. 2. Download files by: a. Plug the USB drive into the computer's USB port. b. Select the USB port being used on the computer. c. Confirm choice of USB storage drive. Then click Next. d. After clicking Next, the files will automatically begin downloading. NOTE DO NOT REMOVE THE USB DRIVE UNTIL THE DOWNLOAD IS COMPLETE. THE SCREEN WILL CONFIRM THAT THE DOWNLOAD IS COMPLETE. e. Safely remove the USB storage drive from the computer's USB port by clicking on the Windows personal computer (PC) Safely Remove Hardware icon at the bottom right of the screen, next to the clock. 3. Install files by: a. Insert USB storage drive into the vehicle's Sync USB port. b. Turn on both, the vehicle and radio. NOTE IT IS RECOMMENDED TO HAVE THE VEHICLE RUNNING (WITH PROPER EXHAUST VENTILATION) AND NOT IN THE ACCESSORY MODE. THIS IS TO ENSURE THE VEHICLE'S BATTERY SUPPLY VOLTAGE REMAINS STABLE DURING THE PROGRAMMING PROCESS. c. Select User Device. d. Select Settings. e. Select Install. Display will change to Begin Installation? f. Select Yes. Installing file - will display on the screen. NOTE DO NOT REMOVE THE USB DRIVE WHILE THE INSTALLATION IS IN PROGRESS. g. Upon completion of downloading of files, Installation Complete will display on the Sync screen. h. The Sync voice will say, Installation complete. Sync may also say, The system will now reboot. Please wait a few moments before using the system. Installation Complete will remain on the Sync display until you exit the installation mode. i. Select the Menu radio button to exit installation mode. j. Remove the USB storage drive. k. Consumer takes their USB storage drive back to their computer to report the successful install. (This feature allows for tracking and determining if the consumers vehicle has a newer version available for downloading or not.) NOTE ADDITIONAL INFORMATION AND DETAILS ARE AVAILABLE ON THE SYNCMYRIDE.COM WEBSITE. REGISTERED SYNC OWNERS WILL SEE VEHICLE SPECIFIC DETAILS AND DIRECTIONS BASED ON THEIR VEHICLE'S OPTION CONTENT. APIM Programming Using IDS This method programs both, the Vehicle Interface Processor (VIP) (through the data link connector) and CIP (through the USB port), portions of the APIM module. NOTE Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3784 SOFTWARE PACKAGES OBTAINED THROUGH THE PROFESSIONAL TECHNICIAN SOCIETY (PTS) WEBSITE CONTAINS BOTH, VIP AND CIP FILES, THESE DO NOT NEED TO BE INSTALLED IN SEQUENCE LIKE THE CONSUMER DOWNLOAD SERVICE PACK UPDATES, BUT THE ENTIRE PACKAGE MUST BE INSTALLED DURING REPROGRAMMING FOR PROPER OPERATION. THESE SOFTWARE PACKAGES ARE MUCH LARGER IN SIZE AND CONTAIN ALL THE PREVIOUS LEVELS OF ENHANCEMENTS AND UPDATES AS WELL AS ANY ADDITIONAL ENHANCEMENTS AND UPDATES FOR BOTH THE VIP AND CIP PROCESSORS LOCATED IN THE APIM MODULE. NOTE YOU WILL NOT HAVE THE ABILITY TO RESTORE THE PREVIOUS LEVEL OF SYNC OPERATING SOFTWARE ONCE THE APIM MODULE HAS BEEN SUCCESSFULLY UPDATED TO THE NEXT HIGHER LEVEL. NOTE If a new APIM is being installed, install the new APIM before carrying out the following procedure. For additional information, refer to Workshop Manual (WSM), Section 415-00. It is recommended to install a battery charger to the vehicles battery and set at the low charge setting and insure the PC being used for reprogramming is fully charged or plugged into a power source prior to starting the reprogramming process. 1. Turn the ignition key to the On position. 2. Turn the audio control module (ACM) on. 3. Connect the scan tool to the data link connector (DLC). 4. Connect one end of the USB male-A to male-A cable Rotunda part number CCMUSB2-AM-AM-10 (1-800-Rotunda option 6) or equivalent to the scan tool. Compatible cables. (Figures 1) Non-compatible cables. (Figure 2) 5. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 6. From the technician service publication website, run OASIS using Quick Start or by manually entering the vehicle identification number (VIN). 7. From the OASIS tab, select the Sync/APIM bullet. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3785 8. Select the Read APIM button to verify the current APIM VIP and CIP software levels. NOTE DO NOT DISCONNECT THE VEHICLE COMMUNICATION MODULE (VCM) OR USB CABLES DURING APIM PROGRAMMING. 9. Select the desired software level from the list of available software for programming then select the Program APIM button to begin the APIM programming process. Enter the APIM As-Built data if prompted. a. When only the CIP is being programmed, select cancel when prompted whether or not to program the VIP. b. When the VIP is programmed, the CIP will be programmed automatically. 10. The Sync/APIM application downloads the software into the APIM and displays Programming has been completed successfully. 11. Test the audio system for correct operation. PC requirements for successful reprogramming an APIM module. Ford And LIM Logon Issues - Including Proper Browser Settings The following list will have you check various computer settings to insure your PC is set to the proper configuration for reprogramming an APIM module. NOTE CHANGES TO PC SETTINGS MAY REQUIRE ADMINISTRATOR ACCESS. 1. Do not use a customized browser like AOL, it will not work. Please use Internet Explorer (IE) version 5.5 5P2, 6.0, or higher. 2. Log into website. 3. Navigate to PTS (Professional Technician Society) under the Technical Tools on the Parts and Service tab. 4. Check IE settings by completing the following: a. Preliminary Checks. NOTE THESE INSTRUCTIONS APPLY TO WINDOWS XP MACHINES WITH 5P2 AND IE 6.0 AND ABOVE. (1) Open IE, select Tools at the top of the screen and select Security. (2) Click on the Internet Zone, and find Navigate Sub-frames across different domains and enable this function. (3) Then click OK, system may ask you if you want to accept these function please select Yes. (4) Check the Windows Firewall to make sure it is turned off by: (a) Selecting the Start button. (b) Select Control Panel. (c) Select Windows Firewall (if you do not see the icon, make sure you are using Classic View) and set to off. (5) Check Windows Pop-up Blocker to make sure it is turned off. (a) Open IE. (b) Select Tools at the top of the screen. (c) Select Pop-up Blocker and turn it off. (6) Remove any add-on toolbars such as Google or Yahoo toolbars, as these have additional built in pop-up blockers. (7) Verify that any third party anti-virus, anti-spyware, firewall, or internet security software is temporarily disabled. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3786 b. Browser Settings - Open IE and select Internet Options under the Tools heading. (1) Select the General tab (2) Select Delete Files and check the Delete all offline content and select OK (3) Select Delete Cookies and click OK (4) Select Clear History and select Yes. (5) Click on the Security tab. (6) Click on the Trusted Sites icon. (7) Click on Sites. (8) In the box below add this website to the zone type in - website. (9) Ensure that required server verification (https:) for all sites in this zone is not checked. (10) Click the Add button. (11) Click the Close button. (12) Re-select the Security tab and select Custom Level. (13) Under Reset Custom Settings, pull down and Reset to: Low, select Reset, select Yes and then OK. NOTE IF RUNNING OASIS ON IE 7.0, RESET TO: MEDIUM-LOW. ALSO, UNDER SETTINGS, SCROLL TO NAVIGATE SUB-FRAMES ACROSS DIFFERENT DOMAINS, SET TO ENABLED AND CLICK OK. (14) Select the Privacy tab, and move the slider to Low. (15) Click on the Advanced, check the box Override automatic cookie handling and check the box to Always allow session cookies' and click OK. (16) Select the Advanced tab and scroll down to HTP 1.1 settings; make sure both options under this section are checked. (17) Scroll down to Security section and make sure the following are checked: (a) Empty Temporary Internet folder when browser is closed. (b) Use SSL 2.0. (c) Use SSL 3.0. (d) Use TLS 1.0. (e) Select Apply and then click on OK. 5. Close all browsers and reboot the computer to have the browser settings take affect properly. The browser settings have now been setup correctly as per Ford Browser settings recommendations. Additional PC Security Settings (May Or May Not Be Required - Depends On Operating System) Changes to PC Security Settings may require Administrator access. 1. Check for Information Bar near top of IE page stating - This website wants to run the following add-ons. 2. Click on Information Bar and select Run ActiveX Controls or Temporarily Allow Pop-ups depending on your operating system. 3. Click on Retry button to refresh information. (May not be required on some operating systems) PC and Server Troubleshooting (Optional) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-21-2 > Oct > 08 > Computers/Controls - Sync Software Programming > Page 3787 ^ If you wish to test another browser for web-based training only, download the free version of Opera at www.Opera.com. ^ For web-based training sound problems, make sure your firewall allows downloading sound file types such as MP3. ^ If you have installed special search and add-on programs such as Gator or Bonzi please remove them. ^ If you have a router, make sure that port 443 is open for Secure Socket Layer (SSL), and ports 80 and 8080 are open for HTTP. ^ Internet access uses a caching or proxy server. Make sure the caching/proxy servers are set to automatically detect settings. Contact your local network administrator and/or your Internet service provider and have them turn off the caching on any and all caching proxy servers for the following: ^ Uniform Resource Locator (URL): www.proservicetech.com or ford website Additional Sync Related Service Tips 1. Performing a Master Reset of the APIM module or removing and restoring the Keep Alive Power circuit fuse (refer to the appropriate wiring manual) for 3-minutes, prior to reprogramming will restore the factory APIM defaults. This can reduce the possibilities of corrupt files, that may have been transferred into the APIM modules memory, from interfering with the reprogramming of the CIP portion of the APIM module. 2. Non-factory installed items that can cause background noise, wind noise or obstruct the voice path to the Sync system's microphone, will reduce the reliability or accuracy of the consumer's voice commands or speech being recognized properly. Some examples may include but are not limited to: ^ Objects hanging from the rear view mirror that may make noise or obstruct the system microphone located on the mirror. ^ Bug shields. ^ Roof mounted accessories. ^ Damaged window moldings. ^ Non-factory installed overhead consoles or sun-visor storage compartments that obstruct the voice path to the systems microphone. (It is recommended when diagnosing voice recognition or phone call sound quality issues to eliminate these types of items before replacing any system components) 3. Remote Starts may prevent the Automatic Discovery Process, of previously paired phones, from connecting with the consumer's phone as it may be outside of the device's Bluetooth reception range. Once the vehicle is started remotely, the Sync system automatically begins to search for previously paired phones; eventually this process will time out if the customers phone does not enter the vehicle prior to the expiration of this internal timer, resulting in the vehicle Sync not automatically recognize the phone and pair with it. If this occurs, once the customer enters the vehicle, the consumer will be required to manually connect the phone through the Sync menus if they would like to use the hands free phone features. NOTE THE CONSUMER WILL NOT BE REQUIRED TO PAIR THE PHONE AGAIN. 4. When Reprogramming APIM modules, it is strongly recommended to use a hard wired internet connection if possible, due to the APIM program file sizes. If a wired internet connection is not available, it is recommended to access the PTS website and download the latest Sync software files from the Tech Central tab prior to reprogramming. This will reduce the overall reprogramming time when you are connected to the vehicle. If error messages appear during the reprogramming process that indicate errors with the VIP or CIP file/image, comparing the saved file/image by checking the file size, between your PC/IDS with the available file/image size indicated in the PTS description can help determine if the file may be corrupt or damaged. If this has occurred or is suspected, re-download the file/image and select Yes when asked Do you want to replace it? 5. Always diagnose and repair any DTC's for the Audio system or any module communication related faults prior to APIM reprogramming. WARRANTY STATUS: Information Only - Not Warrantable Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal 1. Remove the front floor console. 2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector. 3. Remove the screw and the BSIA. Installation 1. Install the BSIA and the screw. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 3794 2. Connect the BSIA electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. With the ignition ON, press the 4X4 HIGH button on the Mode Select Switch (MSS). 3. Remove the 3 heat shield bolts and the heat shield. - To install, tighten to 16 Nm (142 lb-in). 4. Disconnect the transfer case shift motor electrical connector. 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 3799 7. To install, reverse the removal procedure. - Apply a coat of multi-purpose grease to the transfer case shift motor bolts. - Apply a thin coat of silicone sealant to the shift motor mating surface. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal 1. Remove the front floor console. 2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector. 3. Remove the screw and the BSIA. Installation 1. Install the BSIA and the screw. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 3805 2. Connect the BSIA electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 3814 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 (V6-4.0L (2009)) 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 3815 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 (V6-4.0L (2009)) 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 3816 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 (V6-4.0L (2009)) 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 3817 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 3823 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 (V6-4.0L (2009)) 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 3824 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 (V6-4.0L (2009)) 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 3825 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 (V6-4.0L (2009)) 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 3826 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 3838 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 (V6-4.0L (2009)) 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 3839 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 (V6-4.0L (2009)) 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 3840 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 (V6-4.0L (2009)) 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 3841 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 3847 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 (V6-4.0L (2009)) 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 3848 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 (V6-4.0L (2009)) 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 3849 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 (V6-4.0L (2009)) 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 3850 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3859 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3860 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3866 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3867 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY 5R55S .................................................................................................................................................. ............................................. 12.4 quarts (11.7 liters) 6R80 ................................................................ .................................................................................................................................. 11.2 quarts (10.6 liters) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3872 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION FLUID 5R55S .................................................................................... ........................................................................................... [1] Motorcraft MERCON V ATF Ford Part Number ................................................................................................................................................ .................................................. XT-5-QM Ford Specification ............................................................. ................................................................................................................................ MERCON V 6R80 .................................................................................................................................................... ........................... [2] Motorcraft MERCON LV ATF Ford Part Number ............................................... ................................................................................................................................................ XT-10-QLV Ford Specification ............................................................................................................. .............................................................................. MERCON LV Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S Fluid - A/T: Service and Repair 5R55S Transmission Fluid Level Check Transmission Fluid Level Check Transmission Fluid Fill Reference NOTE: Left side of case shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3875 1. Using the scan tool, monitor the Transmission Fluid Temperature (TFT). 2. Start the engine. 3. NOTE: Engine idle speed is approximately 650 rpm. Run the engine until the TFT is between 27-49°C (80-120°F). 4. Move the selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. 5. Place the selector lever in the PARK position. 6. With the engine running and the vehicle set as close to level as possible, position it on a hoist. 7. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. 8. Install the Fluid Level and Fill Plug Adapter into the pan. 9. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure that the canister is clean. Fill the Fluid Transporter/Evacuator/Injector with transmission fluid. 10. Hang the Fluid Transporter/Evacuator/Injector under the vehicle. Position it upright and close to the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3876 11. Connect the Fluid Transporter/Evacuator/Injector. - Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 12. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the Rubber Tip Air Nozzle. Transmission fluid will immediately start flowing out of the Fluid Transporter/Evacuator/Injector into the transmission fluid pan. 13. Add 0.5L (1 pt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the Rubber Tip Air Nozzle from the end of the hose. 14. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. If the transmission fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 12 and 13. 15. Once the transmission is full, place a Vacuum Pump Kit on the open end of the vacuum/pressure hose on the Fluid Transporter/Evacuator/Injector and apply vacuum to the system. This will pull out any extra transmission fluid trapped in the system and direct it into the container. 16. Allow the transmission fluid to drain. Make sure that the TFT is between 27-49°C (80-120°F). When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. 17. Reinstall the small (center) transmission fluid level indicating plug. - Tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3877 18. Check the operation of the transmission by moving the selector lever slowly through each gear, stopping in each position and allowing the transmission to engage. Transmission Fluid Exchange Transmission Fluid Exchange NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products can cause internal transmission components to fail, which will affect the operation of the transmission. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid. 3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission fluid cooler tube after the transmission fluid cooler on the return tube. This will help remove any foreign material trapped in the transmission fluid coolers. 4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Follow the manufacturer's instructions included with the machine. 5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Reconnect any disconnected transmission fluid cooler tubes. 6. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3878 Fluid Fill Reference NOTE: Left side of case shown. Draining Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3879 1. With the vehicle in PARK, position it on a hoist. Set the vehicle as close to level as possible. 2. Remove the transmission fluid drain plug (large plug) and allow the transmission fluid to drain. Refill 1. Install the transmission fluid drain plug. - Tighten to 26 Nm (19 lb-ft). 2. Hold the larger transmission fluid drain plug with a wrench and remove the small (center) transmission fluid level indicating plug. 3. Install the Fluid Level and Fill Plug Adapter into the transmission fluid pan. 4. NOTE: Prior to filling the Fluid Transporter/Evacuator/Injector with transmission fluid, make sure that the canister is clean. Fill the Fluid Transporter/Evacuator/Injector with transmission fluid. 5. Hang the Fluid Transporter/Evacuator/Injector under the vehicle, upright and close to the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3880 6. Connect the Fluid Transporter/Evacuator/Injector. - Connect the open end of the fluid hose from the Fluid Transporter/Evacuator/Injector to the Fluid Level and Fill Plug Adapter at the bottom of the transmission fluid pan. 7. Apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the Rubber Tip Air Nozzle. Transmission fluid will immediately start flowing out of the Fluid Transporter/Evacuator/Injector into the transmission fluid pan. 8. Add 1.89L or 2.83L (2 qt or 3 qt) of transmission fluid into the transmission fluid pan. Stop the process by releasing the air pressure and removing the Rubber Tip Air Nozzle from the end of the hose. 9. NOTE: Engine idle speed is approximately 650 rpm. Using the scan tool, start and run the engine until the Transmission Fluid Temperature (TFT) is between 27°C-49°C (80°F-120°F). 10. Inspect the transmission fluid level in the Fluid Transporter/Evacuator/Injector. If the fluid drains back into the canister, the transmission is full. If no transmission fluid drains back, more transmission fluid will need to be added. Repeat Steps 9 and 10. 11. Once the transmission is full, place a hand Vacuum Pump Kit on the open end of the vacuum/pressure hose on the Fluid Transporter/Evacuator/Injector and apply vacuum to the system. This will pull out any extra fluid trapped in the system and direct it into the container. 12. Allow the transmission fluid to drain. When the transmission fluid comes out as a thin stream or drip, the transmission fluid is at the correct level. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3881 13. Reinstall the small (center) transmission fluid level indicating plug. - Tighten to 10 Nm (89 lb-in). Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning NOTICE: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or Oil-To-Air (OTA), if equipped, will need to be installed. Failure to follow these instructions may result in transmission failure. NOTICE: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler tubes, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler tubes as described. Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube). - Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. 6. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission cooler return tube) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3882 Fluid - A/T: Service and Repair 6R80 Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Drain 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Some transmission fluid leakage may occur when removing the transmission fluid fill plug. Remove the transmission fluid fill plug fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3883 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket, if required. 5. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. - Tighten to 12 Nm (106 lb-in). Transmission Fluid Refill NOTICE: This procedure contains the air purge steps required to purge air from the transmission fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check. NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. NOTICE: The transmission fluid fill plug is located near the exhaust system. The exhaust will be extremely hot during this procedure. NOTICE: 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 transmission fluid leaking, the transmission 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 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 fluid cooling system. - Fill the transmission fluid to the fill range on the transmission 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 transmission fluid added to the transmission as an initial fill if: - the transmission has been overhauled. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3884 - a new mechatronic assembly has been installed. - the transmission fluid pan or transmission fluid filter have been removed. Using the Transmission Fluid Fill Tube, add 3.3L (3.5 qt) of transmission fluid to the transmission through the transmission fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in this procedure. 2. Check the transmission fluid level cold. - 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 with the engine running, place the selector lever in each gear position and hold approximately 5 seconds. Place the selector lever in PARK, with the engine at idle (600-750 rpm). 3. Separate the transmission fluid level indicator from the transmission fluid fill plug. 4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 5. Add transmission fluid to the cold level location as shown in the illustration. 6. Install the transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). 7. While driving the vehicle, use the scan tool to verify that the Transmission Fluid Temperature (TFT) has reached a temperature of 88°C (190°F). This will circulate the transmission fluid through the torque converter and the transmission fluid cooling system, eliminating any trapped air in the transmission fluid cooling system. With the engine idling (600-750 rpm) in PARK, verify that the TFT is between 80°C-85°C (175°F-185°F). 8. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3885 9. Separate the transmission fluid level indicator from the transmission fluid fill plug. 10. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 11. Using the scan tool verify that the TFT is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark. 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 transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). Adding Additional Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. Install the Transmission Fluid Fill Tube into the transmission fluid fill hole. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3886 2. Fill the Transporter Fluid Evacuator/Injector with approximately 0.47L (1 pt) of transmission fluid. 3. Hang the Transporter Fluid Evacuator/Injector under the vehicle, upright and close to the transmission. 4. Connect the Transporter Fluid Evacuator/Injector and Transmission Fluid Fill Tube. - Connect the open end of the fluid hose from the Transporter Fluid Evacuator/Injector onto the Transmission Fluid Fill Tube from the transmission case. 5. Use a Rubber Tip Air Nozzle to apply a maximum of 206.85 kPa (30 psi) to the open end of the vacuum/pressure hose from the Transporter Fluid Evacuator/Injector. Transmission fluid will immediately start flowing out of the Transporter Fluid Evacuator/Injector into the transmission. 6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3887 7. Using the scan tool, verify that the TFT is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark. 8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this procedure. Install the transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). Removing Transmission Fluid NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in PARK. 1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the Transporter Fluid Evacuator/Injector and the Vacuum Pump Kit to extract any excessive transmission fluid. 2. Using the scan tool, verify that the TFT is between 80°C-85°C (175°F-185°F). The transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a consistent reading is established. 3. Install the transmission fluid fill plug. - Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3888 Transmission Fluid Exchange Transmission Fluid Exchange NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products can cause internal transmission components to fail, which will affect the operation of the transmission. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid. 3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission fluid cooler tube after the transmission fluid cooler on the return tube. This will help remove any foreign material trapped in the transmission fluid coolers. 4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Follow the manufacturer's instructions included with the machine. 5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission and Power Steering Fluid X-Changer. Reconnect any disconnected transmission fluid cooler tubes. 6. Using the scan tool with the engine running, check and make sure that the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved. Transmission Fluid Level Check Transmission Fluid Level Check Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3889 NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure could result. NOTICE: The transmission 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 transmission fluid must cool down to obtain an accurate reading. NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the transmission fluid level should be checked. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the crosshatch mark. NOTE: If the installation of a new transmission fluid cooler or transmission fluid cooler tubes has 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 transmission fluid 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. 3. Remove the transmission fluid fill plug transmission fluid level indicator assembly, located on the passenger side front portion of the transmission case. 4. Separate the transmission fluid level indicator from the transmission fluid fill plug. 5. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to check the transmission fluid level. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 5R55S > Page 3890 6. Using the scan tool, verify that the Transmission Fluid Temperature (TFT) is between 80°C-85°C (175°F-185°F). Do not overfill the transmission. The transmission 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. For additional information, refer to Transmission Fluid Drain and Refill See: Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill. Install the transmission fluid fill plug. Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S Fluid Filter - A/T: Service and Repair 5R55S Fluid Pan, Gasket and Filter Fluid Pan, Gasket and Filter Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission fluid pan. 3. Remove the transmission fluid pan drain plug and drain the transmission fluid. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 3895 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Installation 1. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid filter. - Tighten to 10 Nm (89 lb-in). 2. Install the transmission fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan gasket on the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 3896 4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws in a crisscross sequence. - Tighten to 11 Nm (97 lb-in). 6. Install the transmission fluid pan drain plug. - Tighten to 26 Nm (19 lb-ft). 7. Partially fill the transmission. For additional information, refer to Transmission Fluid Exchange See: Service and Repair/Procedures/5R55S/Transmission Fluid Exchange or Transmission Fluid Drain and Refill See: Service and Repair/Procedures/5R55S/Transmission Fluid Drain and Refill. Transmission Filter - In Line Transmission Filter - In Line Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 3897 NOTE: Use the following guidelines for installing the transmission fluid in-line filter: - If the transmission was overhauled and the vehicle was equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter. - If the transmission was overhauled and the vehicle was not equipped with an in-line transmission fluid filter, install a new in-line transmission fluid filter kit. - If the transmission is being installed for a non-internal repair, do not install an in-line transmission fluid filter or in-line transmission fluid filter kit. - If installing a Ford-authorized remanufactured transmission, install a new in-line transmission fluid filter. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the transmission fluid cooler connector. 3. Using the Transmission Disconnect Tool, disconnect the transmission fluid cooler connector. 4. Remove the section of the transmission fluid cooler tube at the second flare. - Clean and de-burr the cut end of the transmission fluid cooler tube. 5. NOTE: Be sure the transmission fluid cooler tube is fully seated in the body of the fitting before final tightening of the ferrule nut. Install the tubing ferrule hose assembly connector onto the end of the transmission fluid cooler tube. Finger-tighten the ferrule nut, then tighten the nut an additional one and one-half turns to seat the ferrule in the connector. 6. Remove the section of the transmission fluid cooler hose as illustrated. 7. NOTICE: The transmission fluid cooler filter has a bypass valve in it. The red arrow on the transmission fluid filter indicates the direction of transmission fluid flow through the filter. The transmission fluid filter must be installed in the transmission fluid cooler return tube with the red arrow on the transmission fluid filter pointing away from the transmission fluid cooler and toward the transmission (the transmission fluid return tube has transmission fluid coming out of the transmission fluid cooler going to the transmission). If the transmission fluid filter is not installed correctly, it will cause internal transmission damage. NOTICE: Do not install any transmission fluid cooler hoses or transmission fluid cooler tubes with a bend entering the transmission fluid Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 3898 filter greater than 60 degrees. Doing so can block transmission fluid flow and cause internal transmission damage. Install the one end of the transmission fluid filter into the transmission fluid cooler hose with a clamp. - Tighten the transmission fluid cooler hose clamp. 8. Using a suitable length of hose, install the other end of the transmission fluid filter into the tubing ferrule hose assembly with 2 clamps. - Tighten the hose clamps. 9. Clean a section of the transmission fluid pan, then install the sticker. 10. Fill the transmission with transmission fluid. - Verify for correct operation. - Check the filter for leaks. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 3899 Fluid Filter - A/T: Service and Repair 6R80 Fluid Pan, Gasket and Filter Removal NOTICE: The use of any transmission fluid other 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. 2. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. Remove the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 3900 Installation NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission fluid filter and seal assembly. The transmission 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 automatic transmission fluid. 3. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated. Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if required. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 5R55S > Page 3901 6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. - Tighten to 12 Nm (106 lb-in). 7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid. For additional information, refer to Transmission Fluid Drain and Refill See: Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 5R55S Fluid Pan: Specifications 5R55S Tighten the transmission fluid pan screws in a crisscross sequence. Tighten to................................. .............................................................................................................................................................. .......11 Nm (97 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 5R55S > Page 3906 Fluid Pan: Specifications 6R80 Install the transmission fluid pan and tighten the bolts in a crisscross pattern. Tighten to................... .............................................................................................................................................................. ...................12 Nm (106 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S Fluid Pan: Service and Repair 5R55S Fluid Pan, Gasket and Filter Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place a drain pan under the transmission fluid pan. 3. Remove the transmission fluid pan drain plug and drain the transmission fluid. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S > Page 3909 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Installation 1. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid filter. - Tighten to 10 Nm (89 lb-in). 2. Install the transmission fluid pan magnet in the transmission fluid pan. 3. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan gasket on the transmission fluid pan. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S > Page 3910 4. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan screws. 5. Tighten the transmission fluid pan screws in a crisscross sequence. - Tighten to 11 Nm (97 lb-in). 6. Install the transmission fluid pan drain plug. - Tighten to 26 Nm (19 lb-ft). 7. Partially fill the transmission. For additional information, refer to Transmission Fluid Exchange See: Service and Repair/Procedures/5R55S/Transmission Fluid Exchange or Transmission Fluid Drain and Refill See: Service and Repair/Procedures/5R55S/Transmission Fluid Drain and Refill. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S > Page 3911 Fluid Pan: Service and Repair 6R80 Fluid Pan, Gasket and Filter Removal NOTICE: The use of any transmission fluid other 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. 2. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. 3. Remove the transmission fluid pan and allow the transmission fluid to drain. 4. Remove the transmission fluid pan gasket. 5. Remove and discard the transmission fluid filter. 6. Clean and inspect the transmission fluid pan and magnet. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S > Page 3912 Installation NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission fluid filter and seal assembly. The transmission 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 automatic transmission fluid. 3. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated. Install a new transmission fluid filter. 4. Position the magnet in the transmission fluid pan. 5. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket if required. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Service and Repair > 5R55S > Page 3913 6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern. - Tighten to 12 Nm (106 lb-in). 7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid. For additional information, refer to Transmission Fluid Drain and Refill See: Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3927 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3928 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3934 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 3935 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S Seals and Gaskets: Service and Repair 5R55S Extension Housing Seal Extension Housing Seal - Four Wheel Drive (4WD) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transfer case assembly. 3. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the extension housing seal. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3940 Installation 1. NOTE: Make sure the extension housing seal is correctly installed onto the Extension Housing Seal Installer and the garter spring is in the correct position. Using the Extension Housing Seal Installer, install the extension housing seal. 2. Install the transfer case assembly. 3. Carry out the transmission fluid level check. For additional information, refer to Transmission Fluid Level Check See: Service and Repair/Procedures/5R55S/Transmission Fluid Level Check. Extension Housing Gasket Extension Housing Gasket - Four Wheel Drive (4WD) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Support the transmission with a suitable jack. 3. Remove the transfer case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3941 4. NOTE: The park pawl, park pawl return spring and park pawl shaft may fall out during removal of the extension housing. Remove the extension housing. 5. Remove and discard the extension housing gasket. Installation 1. Clean the extension housing and install new extension housing gasket. Make sure that the park pawl is installed correctly. 2. NOTE: Verify the park lever actuating rod is correctly seated into the case park rod guide cup. Install the extension housing and the extension housing screws. - Tighten to 30 Nm (22 lb-ft). 3. Install the transfer case. 4. Remove the transmission support jack. 5. Carry out the transmission fluid level check. For additional information, refer to Transmission Fluid Level Check See: Service and Repair/Procedures/5R55S/Transmission Fluid Level Check. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3942 Seals and Gaskets: Service and Repair 6R80 Output Shaft Seal Output Shaft Seal NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3943 Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 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. 4. Remove the extension housing flange seal and the output shaft flange. 5. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal. 6. Remove the slip plane washer. Four-Wheel Drive (4WD) vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3944 7. Remove the transfer case. 8. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal. Installation RWD vehicles 1. Install the slip plane washer. 2. Position a new output shaft seal. 3. Using the 6R80 Rear Seal 4X2 Installer, install the output shaft seal. 4. Install the output shaft flange. 5. Install the extension housing flange seal and a new output shaft flange nut. - Tighten to 80 Nm (59 lb-ft). - After installing the new output shaft flange nut, it must be staked at the slots to prevent it from coming loose. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3945 6. Install the rear driveshaft. 4WD vehicles 7. Position the output shaft seal. 8. Using the 6R80 Rear Seal 4X4 Installer, install a new output shaft seal. 9. Install the transfer case. All vehicles 10. Fill and check the transmission fluid. For additional information, refer to Transmission Fluid Level Check See: Service and Repair/Procedures/6R80/Transmission Fluid Level Check. Manual Control Lever Shaft and Seal Manual Control Lever Shaft and Seal Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable heat shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3946 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Move the locking tab up and disconnect the transmission selector lever cable end from the manual control lever ball stud. 1. Locking tab. 2. Selector lever cable end. 4. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. 5. Remove the transmission fluid pan and allow the transmission fluid to drain. 6. Remove and discard the transmission fluid filter. 7. Remove the transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3947 8. NOTICE: 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. 9. Pull the release tab and pull down on the bulkhead connector retainer. 10. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission vehicle harness connector. Electrostatic discharge may occur and may cause damage to the mechatronic unit. With the release tab down, pull the outer shell of the transmission vehicle harness connector out of the mechatronic assembly. 11. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the mechatronic unit. Electrostatic discharge may occur and may cause damage to the mechatronic unit. Pull the transmission vehicle harness electrical connector out of the transmission. 12. NOTICE: During removal of the mechatronic assembly, the thermal bypass valve will fall out of the transmission case. Damage to the valve will occur if the valve falls out. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly and the bypass valve. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3948 13. Remove the park rod actuating plate. 14. 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. 15. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3949 2. Using the Shift Shaft Fluid Seal Installer, 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 rod actuating plate. - Tighten to 12 Nm (106 lb-in). 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 tubes. 2. Green feed tube. 3. Blue feed tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3950 7. Verify the rubber adapter is in place. 8. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal bypass valve in the transmission case. 9. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission vehicle harness connector. 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. 10. Tighten the mechatronic bolts in the sequence shown. - Tighten to 8 Nm (71 lb-in). 11. NOTICE: Do not touch the electrical connector pins. Electrostatic discharge may occur and will cause damage to the mechatronic unit. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3951 With the release tab down and unlocked, push the outer shell of the transmission vehicle harness connector into the transmission. Make sure that the transmission vehicle harness connector is fully seated into the mechatronic assembly. 12. Press up on the tab and lock the outer shell of the transmission vehicle harness connector in place. 13. Install a new transmission fluid filter. 14. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket, if necessary. 15. Install the transmission fluid pan and tighten the transmission fluid pan bolts in a crisscross pattern. - Tighten to 12 Nm (106 lb-in). 16. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 5R55S > Page 3952 17. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. With the manual lever in NEUTRAL, connect the selector lever cable onto the manual control lever ball stud and move the locking tab down. 1. Selector lever cable end. 2. Locking tab. - Listen for the audible click. - Pull back on the selector lever cable to make sure that it is correctly installed. 18. Install the selector lever cable heat shield. 19. Using the refill procedure, fill and check the transmission fluid. For additional information, refer to Transmission Fluid Drain and Refill See: Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Mode Switch: Description and Operation Engine Control Components 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. Typical Transmission Control Switch (TCS) (Column Shift) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) (Floor Shift) Typical Transmission Control Switch (TCS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS) External Controls Transmission Control Switch (TCS) The Transmission Control Switch (TCS) is a momentary contact switch located on the selector lever knob. Pushing the TCS will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on the Instrument Cluster (IC). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) > Page 3962 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See: Shifter A/T/Service and Repair/Selector Lever Knob. 2. Remove the Transmission Control Switch (TCS) from the knob. Installation 1. Install the TCS into the selector lever knob. 2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See: Shifter A/T/Service and Repair/Selector Lever Knob. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3966 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3967 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3968 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3969 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3970 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3971 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3972 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3973 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3974 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3979 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3980 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3981 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 3984 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 3985 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor 5R55S Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3988 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Turbine Shaft Speed (TSS) sensor connector. 8. Remove the TSS sensor. 1. Remove the TSS sensor screw. 2. Remove the TSS sensor from the transmission. - Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3989 Installation All vehicles 1. Inspect the TSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the TSS sensor into the transmission. 2. Tighten the TSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the TSS sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever bracket and selector lever bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3990 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3991 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor 5R55S Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3992 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Heated Oxygen Sensor (HO2S) connector from the transmission case. 8. Disconnect the Output Shaft Speed (OSS) sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3993 9. Remove the OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the OSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the OSS sensor into the transmission. 2. Tighten the OSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the OSS sensor connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3994 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3995 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3996 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor 5R55S Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3997 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor connector. 8. Remove the intermediate shaft speed sensor. 1. Remove the intermediate shaft speed sensor screw. 2. Remove the intermediate shaft speed sensor from the transmission. - Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3998 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the intermediate shaft speed sensor into the transmission. 2. Tighten the intermediate shaft speed sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the intermediate shaft speed sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3999 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal 1. Remove the front floor console. 2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector. 3. Remove the screw and the BSIA. Installation 1. Install the BSIA and the screw. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 4004 2. Connect the BSIA electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal 1. Remove the front floor console. 2. Disconnect the selector lever cable from the selector lever. 3. Disconnect the selector lever cable from the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4009 4. Disconnect the selector lever housing electrical connector. 5. Disconnect the wiring harness from the selector lever housing. 6. Remove the 4 nuts and remove the selector lever housing from the vehicle. Installation 1. Install the selector lever housing. - Tighten to 9 Nm (80 lb-in). 2. Connect the wiring harness to the selector lever housing. 3. Connect the selector lever housing electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4010 4. Install the selector lever cable onto the selector lever housing. 5. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the selector housing. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed onto the selector lever housing. Install the selector lever cable end onto the selector lever housing. 6. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4011 Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Removal 1. Remove the front floor console. 2. Disconnect the Transmission Control Switch (TCS) electrical connector and feed the wire through the selector lever housing. 3. Slide the selector lever knob lower trim cover downward. 4. Remove the set screw and remove the selector lever knob while routing the TCS harness out of the selector lever housing. Installation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4012 1. NOTICE: 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 TCS harness through the selector lever housing. - Tighten to 3 Nm (27 lb-in). 2. Slide the selector lever knob lower trim cover upward. 3. Feed the wire through the selector lever housing and connect the TCS electrical connector. 4. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4013 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Removal 1. Remove the front floor console. 2. Disconnect the Transmission Control Switch (TCS) electrical connector and feed the wire through the selector lever housing. 3. Slide the selector lever knob lower trim cover downward. 4. Remove the set screw and remove the selector lever knob while routing the TCS harness out of the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4014 5. Remove the selector lever bezel from the selector lever housing. Installation 1. Install the selector lever bezel onto the selector lever housing. 2. NOTICE: 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 TCS harness through the selector lever housing. - Tighten to 3 Nm (27 lb-in). 3. Slide the selector lever lower trim cover upward. 4. Feed the wire through the selector lever housing and connect the TCS electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair > Selector Lever > Page 4015 5. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair Shift Cable: Service and Repair Selector Lever Cable Vehicles Equipped With a 6R80 Transmission Vehicles Equipped With a 5R55S Transmission Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front floor console left side panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 4020 3. With the selector lever in PARK, disconnect the selector lever cable from the selector lever. 4. Disconnect the selector lever cable from the selector lever housing. 5. Pull the selector lever cable and grommet through the floorpan. Vehicles equipped with a 6R80 transmission 6. Remove the selector lever cable shield by prying on the selector lever shield closest to the boot, then sliding the shield away from the boot. 7. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Unlock the lock tab and disconnect the selector lever cable end from the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 4021 1. Lock tab. 2. Selector lever cable end. 3. Manual control lever. 8. Disconnect the selector lever cable from the selector lever cable bracket and remove the selector lever cable. Vehicles equipped with a 5R55S transmission 9. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the boot, then sliding the shield away from the boot. 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Unlock the lock tab and disconnect the selector lever cable end from the manual control lever. 11. Disconnect the selector lever cable from the bracket and remove the selector lever cable. Installation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 4022 Vehicles equipped with a 6R80 transmission 1. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable into the selector lever cable bracket. 2. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud and lock the tab. 1. Selector lever cable end. 2. Lock tab. 3. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install and secure the selector lever 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 selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed. 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 4023 ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable into the selector lever cable bracket. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud and lock the tab. 1. Selector lever cable end. 2. Lock tab. 6. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install and secure the selector lever cable shield. All vehicles 7. Push the selector lever cable and grommet through the floorpan. 8. Connect the selector lever cable onto the selector lever housing. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Page 4024 9. Connect the selector lever cable onto the selector lever. 10. Install the front floor 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. For additional information, refer to Selector Lever Cable Adjustment - 5R55S See: Adjustments/External Controls/Selector Lever Cable Adjustment - 5R55S or Selector Lever Cable Adjustment - 6R80 See: Adjustments/External Controls/Selector Lever Cable Adjustment - 6R80. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation Torque Converter: Description and Operation 6R80 Torque Converter The torque converter is a 4-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 the following 4 elements: - Impeller assembly - Turbine assembly - Reactor assembly - Torque Converter Clutch (TCC) Rotation of the torque converter housing and impeller set the transmission fluid in motion by driving the impeller blades and pump. The turbine is driven by the transmission fluid from the impeller and transmits power to the input shaft. The reactor redirects transmission fluid flow returned from the turbine to the impeller so that it rotates in the same direction as the impeller. This action assists in torque multiplication. The reactor has a One-Way Clutch (OWC) to hold it stationary during torque multiplication and allows it to rotate at higher vehicle speeds. Torque Converter Operation Torque Converter Clutch (TCC) The TCC has a cover assembly with a 3-plate clutch and a turbine and damper assembly that connects to the transmission input shaft. The TCC connects the cover to the turbine when the TCC is applied. During TCC release, transmission fluid flows through the torque converter in one direction to release the 3-plate clutch. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > Page 4028 During TCC apply, transmission fluid flows through the torque converter in the opposite direction to apply the 3-plate clutch. The TCC operates in 3 stages: - Full release - Controlled modulation - Full apply The Transmission Control Module (TCM) controls TCC operation using the TCC solenoid. TCC solenoid operation provides the modulation of hydraulic pressure to change the position of the bypass clutch control regulator valve. The valve changes the pressure and direction of transmission fluid flow in the torque converter. The TCC may be applied in forward gears, 2 to 6. Torque Converter Exploded View Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S Torque Converter: Testing and Inspection 5R55S Torque Converter Torque Converter 1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: - A torque converter malfunction has been determined based on complete diagnostic procedures. - Converter stud or studs, impeller hub or bushing are damaged. - Discoloration (due to overheating). - Evidence of transmission assembly or fluid contamination due to the following 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/5R55S/Torque Converter Contamination Inspection. Torque Converter Diagnosis Torque Converter Diagnosis Prior to installing a new torque converter, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of a good torque converter. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary inspection. 2. Know and understand the customer concern. 3. Verify the concern - carry out the Torque Converter Clutch (TCC) Operation Test. Refer to Torque Converter Operation Test. 4. Carry out diagnostic procedures. - Run On-Board Diagnostic (OBD). See On-Board Diagnostics with Scan Tool. Refer to Diagnostics See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/5R55S/Diagnostics. Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun OBD test to verify repair. - Carry out the Line Pressure Test. Refer to Special Testing Procedures See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S/Special Testing Procedures. - Carry out the Stall Speed Test. Refer to Special Testing Procedures. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S/Special Testing Procedures/Stall Speed Test See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/5R55S/Special Testing Procedures - Carry out the Diagnosis by Symptom Index. Refer to Diagnosis By Symptom See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/5R55S/Diagnosis By Symptom. Use the index 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 service as necessary before servicing the torque converter. Torque Converter Operation Test This test verifies that the TCC control system and the torque converter are operating correctly. 1. Carry out the Self Test. See On-Board Diagnostics with Scan Tool. Refer to Diagnostics See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/5R55S/Diagnostics. Check for DTCs. Refer to the Diagnostic Trouble Code (DTC) Charts Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S > Page 4031 See: Transmission Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/5R55S. 2. Connect a scan tool to the vehicle and monitor engine rpm. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds in the (D) position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap the brake pedal with the left foot. 5. The engine rpm should increase when the brake pedal is tapped and decrease about 5 seconds after the pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in Diagnosis By Symptom See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/5R55S/Diagnosis By Symptom. 6. If the vehicle stalls in (D) or MANUAL 2 at idle with the vehicle stopped, move the selector lever to MANUAL 1 position. If the vehicle stalls, refer to Diagnosis By Symptom See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/5R55S/Diagnosis By Symptom, Torque Converter Operation Concerns. Repair as necessary. If the vehicle does not stall in (D), refer to Diagnosis By Symptom See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/5R55S/Diagnosis By Symptom. Torque Converter Contamination Inspection Torque Converter Contamination Inspection 1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: - A torque converter malfunction has been determined based on complete diagnostic procedures. - The torque converter stud or studs, impeller hub or bushing are damaged. - The torque converter exhibits external discoloration (due to overheating). - There is evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes. Major metallic failure - Multiple clutch plates or band failures - Sufficient component wear which results in metallic contamination - Water or antifreeze contamination 2. If none of the above conditions are present, continue with the following fluid inspection. 3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter. 4. Examine the fluid for contaminants, color and smell. The fluid must be free of contaminants, red in color and not have a burnt smell. 5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. If the fluid passed inspection: - drain the remaining fluid from the torque converter. - using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter and agitate by hand. - thoroughly drain the fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S > Page 4032 Torque Converter: Testing and Inspection 6R80 Torque Converter Diagnosis Torque Converter Diagnosis 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 concern. 3. Verify the condition - carry out the Torque Converter Operation Test. 4. Perform diagnostic procedures. - Perform On-Board Diagnostic (OBD) test. Refer to Diagnostics See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/6R80/Diagnostics. Repair all non-transmission related DTCs first. - Repair all transmission-related DTCs. - Rerun OBD test to verify repair. - Perform Stall Speed Test. Refer to Special Testing Procedures See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/6R80/Special Testing Procedures. - Perform Diagnostic Routines. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/6R80/Diagnostic Routines See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/6R80/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. 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. Perform a Self Test with the scan tool. Refer to Computers and Control Systems Information. 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 in the (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 Throttle Position (TP) voltage to approximately 1.25 volts or 25% throttle. 6. Monitor the TCC and RPM TCM PID. The TCC should release and engine rpms should increase before the 5-4 shift occurs. NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as TCC shudder. For diagnosis of the following items, refer to the appropriate systems of the diagnostic/repair information and Computers and Control Systems Information. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > 5R55S > Page 4033 - Spark plugs - check for cracks, high resistance or broken insulators - Spark plug wires - Fuel injector - filter may be plugged - Fuel contamination - engine driveability concerns - 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) and 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 Torque Converter Contamination Inspection Torque Converter Contamination Inspection 1. A new or remanufactured torque converter must be installed if one or more of the following statements is true: - A torque converter malfunction has been determined based on complete diagnostic procedures. - The torque converter stud or studs, impeller hub or bushing are damaged. - The torque converter exhibits external discoloration (due to overheating). - There is evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes. Major metallic failure - Multiple clutch plates or band failures - Sufficient component wear which results in metallic contamination - Water or antifreeze contamination 2. If none of the above conditions are present, continue with the following fluid inspection. 3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or through a paper filter. 4. Examine the fluid for contaminants, color and smell. The fluid must be free of contaminants, red in color and not have a burnt smell. 5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or transmission damage will occur. If the fluid passed inspection: - drain the remaining fluid from the torque converter. - using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter and agitate by hand. - thoroughly drain the fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > General Specifications Transmission Cooler: Specifications General Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > General Specifications > Page 4038 Transmission Cooler: Specifications Material a 5R55S Transmission b 6R80 Transmission Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > General Specifications > Page 4039 Transmission Cooler: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Specifications > Page 4040 Transmission Cooler: Description and Operation Transmission Cooling Vehicles equipped with automatic transmissions have an auxiliary transmission fluid cooler which is mounted in front of the radiator and the A/C condenser. In operation, transmission fluid travels from the transmission to the auxiliary transmission fluid cooler then back to the transmission. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to the outside air. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Inspection and Verification NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler and/or auxiliary cooler should be replaced and the transmission fluid cooler tubes must be cleaned and backflushed to keep contaminants from entering the transmission, causing internal damage. NOTE: Cleaning and backflushing the transmission fluid cooler tubes, 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 failure and must be removed from the transmission cooler system before the transmission is put back into use. Install a new transmission fluid cooler and/or auxiliary cooler and backflush the transmission fluid cooler tubes. When transmission fluid leakage is found in the transmission fluid cooler, install a new transmission fluid cooler. If the fault is not visually evident, GO to Symptom Chart - Transmission Cooling or GO to Symptom Chart - NVH. See: Symptom Related Diagnostic Procedures/Symptom Chart - Transmission Cooling See: Symptom Related Diagnostic Procedures/Symptom Chart - NVH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4043 Transmission Cooler: Symptom Related Diagnostic Procedures Symptom Chart - Transmission Cooling Transmission Cooling Symptom Chart - Transmission Cooling Symptom Chart - Transmission Cooling Symptom Chart - NVH Transmission Cooling Symptom Chart - NVH Symptom Chart - NVH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4044 Transmission Cooler: Component Tests and General Diagnostics Transmission Fluid Cooler 6R80 Transmission Fluid Cooler NOTICE: Whenever a transmission has been disassembled to install new parts, the transmission fluid cooler and/or auxiliary cooler should be replaced and the transmission fluid cooler tubes must be cleaned and backflushed to keep contaminants from entering the transmission, causing internal damage. NOTE: Cleaning and backflushing the transmission fluid cooling tubes, 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 failure and must be removed from the transmission cooling system before the transmission is put back into use. Install a new transmission fluid cooler and/or auxiliary cooler and backflush the transmission fluid cooler tubes. Transmission Fluid Cooler Backflushing and Cleaning 6R80 Transmission Fluid Cooler Backflushing and Cleaning NOTICE: Use only transmission fluid specified for this transmission. Do not use any supplemental transmission fluid additives or cleaning agents. The use of these products could cause internal transmission components to fail; this will affect the operation of the transmission. NOTE: Transmission fluid cooler backflushing and cleaning will be performed using the Turbo-Tank Heated Cooler Line Flusher or equivalent. Follow the manufacturer's instructions included with the machine. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. NOTE: If the vehicle is equipped with an in-line transmission fluid filter, remove and discard the in-line filter. 1. Check and top off fluid level of the Turbo-Tank Heated Cooler Line Flusher or equivalent tank with transmission fluid. 2. Allow the fluid in the Turbo-Tank Heated Cooler Line Flusher or equivalent 15-30 minutes to heat up to 60°C (140°F) before using. 3. Install the line adapters into the transmission cooler lines. 4. Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent red line to the transmission fluid cooler pressure line quick disconnect fitting. 5. Attach the Turbo-Tank Heated Cooler Line Flusher or equivalent blue line to the transmission fluid cooler return line quick disconnect fitting. 6. Follow the equipment instructions to purge the cooler lines and cooler prior to starting the flushing procedure. 7. Allow the cooling system to backflush for 10-15 minutes, then flush the cooler in a normal flow direction for an additional 10-15 minutes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures Transmission Cooler: Procedures 5R55S Transmission Fluid Cooler Backflushing and Cleaning NOTICE: Whenever a transmission has been disassembled to install new parts or a new or remanufactured transmission has been installed, a new transmission fluid cooler, either in-tank, auxiliary or Oil-To-Air (OTA), if equipped, will need to be installed. Failure to follow these instructions may result in transmission failure. NOTICE: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may contain acetone, xylene or heptane to clean and/or flush the transmission assembly, transmission components and the torque converter or transmission damage will occur. Use only transmission fluid designated for the transmission/converter being serviced. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material or band material may have been carried into the transmission fluid cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back in use. 1. Conduct backflushing with a suitable torque converter/transmission fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. Remove and discard the in-line transmission fluid filter, if equipped. 3. To aid in attaching the cleaner to the transmission steel cooler tubes, connect 2 additional rubber hoses to the transmission end of the steel transmission cooler tubes as described. Connect the cleaner tank pressure line to the steel transmission cooler return tube (longest tube). - Connect a tank return hose to the steel transmission cooler pressure tube (shorter tube). Place the outlet end of this hose in the solvent tank reservoir. 4. Turn on the pump and allow the transmission fluid to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in the cooler system). 5. Switch off the pump and disconnect the pressure hose from the transmission cooler return tube. 6. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission cooler return tube) until all the fluid is removed. 7. Remove the rubber return hose from the remaining steel cooler tube. Transmission Fluid Cooler Flow Test - 5R55S Transmission Fluid Cooler Flow Test - 5R55S 1. Refer to Transmission Control Systems. See: Transmission Control Systems/Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4047 Transmission Cooler: Removal and Replacement Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler Removal NOTE: 5R55S uses MERCON(R) V Automatic Transmission Fluid. 6R80 uses Motorcraft MERCON(R) LV Automatic Transmission Fluid. Mountaineer 1. Remove the grille fasteners and the grille. Explorer 2. Remove the front bumper cover. All vehicles 3. Remove the 5 bolts and remove the inner grille air deflector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4048 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. 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 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4049 2. Install the upper transmission fluid cooler bolt. - Tighten to 7 Nm (62 lb-in). 3. NOTE: Clean the transmission cooler tube stems with degreaser prior to installing the hoses. Using new hoses and clamps, install the new transmission fluid cooler hoses. 4. Push the lower air deflector back into place. 5. Install the inner grille air deflector. Mountaineer 6. Install the grille and the fasteners. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4050 Explorer 7. Install the bumper cover. All vehicles 8. Fill the transmission fluid to the correct level using clean transmission fluid and inspect the leaks. Transmission Fluid Cooler Tubes - 5R55S Transmission Fluid Cooler Tubes - 5R55S Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a backup wrench to hold the case fitting securely, disconnect the transmission fluid cooler tubes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4051 3. Remove the secondary latch from the cooler tube. 4. Using the Transmission Cooler Line Disconnect Tool, disconnect the quick connect coupler and remove the transmission fluid cooler tube from the radiator. 5. Remove the secondary latch from the transmission fluid cooler tube. 6. Using the Transmission Cooler Line Disconnect Tool, disconnect the quick connect coupler and separate the transmission fluid cooler tube from the transmission fluid cooler hose. 7. Remove the transmission fluid cooler tube bracket nut. 8. Remove the fluid cooler tube bracket from the stud. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4052 9. Remove the transmission cooler tubes from the vehicle. Installation 1. Install the transmission cooler tubes into the vehicle. 2. Install the transmission fluid cooler tube bracket onto the stud. 3. Verify the case fitting torque. - Tighten to 56 Nm (41 lb-ft). 4. NOTICE: To prevent cross threading, all transmission fluid cooler tube nuts must be hand-started before being tightened to specification. Using a backup wrench to hold the case fittings securely, install the transmission fluid cooler tubes. - Tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4053 5. Install the transmission fluid cooler tube bracket nut. - Tighten to 25 Nm (18 lb-ft). 6. Connect the transmission fluid cooler tube to the transmission fluid cooler hose. 7. Install the secondary latch. 8. Connect the transmission fluid cooler tube to the radiator. 9. Install the secondary latch. 10. Fill transmission fluid to the correct level using clean transmission fluid and inspect for leaks. Transmission Fluid Cooler Tubes - 6R80 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4054 Transmission Fluid Cooler Tubes - 6R80 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the secondary latch from the transmission fluid cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4055 3. Using the Transmission Cooler Line Disconnect Tool, disconnect the quick connect coupler and remove the transmission fluid cooler tube from the radiator. 4. Remove the secondary latch from the transmission fluid cooler tube. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Procedures > Page 4056 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Description and Operation Transmission Mode Switch: Description and Operation Engine Control Components 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. Typical Transmission Control Switch (TCS) (Column Shift) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) (Floor Shift) Typical Transmission Control Switch (TCS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS) External Controls Transmission Control Switch (TCS) The Transmission Control Switch (TCS) is a momentary contact switch located on the selector lever knob. Pushing the TCS will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on the Instrument Cluster (IC). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) > Page 4065 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See: Shifter A/T/Service and Repair/Selector Lever Knob. 2. Remove the Transmission Control Switch (TCS) from the knob. Installation 1. Install the TCS into the selector lever knob. 2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See: Shifter A/T/Service and Repair/Selector Lever Knob. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair 5R55S Transmission Support Insulator - Four Wheel Drive (4WD) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the skid plate bolts and the skid plate. 3. Support the transmission with a transmission jack. 4. Remove the 2 transmission support insulator-to-crossmember nuts. 5. NOTE: Crossmember and exhaust system shown removed. NOTE: LH shown, RH similar. Remove the 2 transmission support insulator-to-extension housing screws. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 4069 6. Raise the transmission and remove the transmission support insulator. Installation 1. Install the transmission support insulator and the 2 transmission support insulator-to-extension housing screws. - Tighten to 90 Nm (66 lb-ft). 2. Lower the transmission and install the 2 transmission support insulator-to-crossmember nuts. - Tighten to 90 Nm (66 lb-ft). 3. If equipped, install the skid plate and skid plate bolts. - Tighten to 24 Nm (18 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4073 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4074 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4075 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4076 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4077 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4078 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4079 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4080 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4081 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4086 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4087 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4088 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4091 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 4092 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor 5R55S Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4095 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Turbine Shaft Speed (TSS) sensor connector. 8. Remove the TSS sensor. 1. Remove the TSS sensor screw. 2. Remove the TSS sensor from the transmission. - Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4096 Installation All vehicles 1. Inspect the TSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the TSS sensor into the transmission. 2. Tighten the TSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the TSS sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever bracket and selector lever bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4097 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4098 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor 5R55S Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4099 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Heated Oxygen Sensor (HO2S) connector from the transmission case. 8. Disconnect the Output Shaft Speed (OSS) sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4100 9. Remove the OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the OSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the OSS sensor into the transmission. 2. Tighten the OSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the OSS sensor connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4101 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4102 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4103 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor 5R55S Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4104 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor connector. 8. Remove the intermediate shaft speed sensor. 1. Remove the intermediate shaft speed sensor screw. 2. Remove the intermediate shaft speed sensor from the transmission. - Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4105 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the intermediate shaft speed sensor into the transmission. 2. Tighten the intermediate shaft speed sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the intermediate shaft speed sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4106 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-4 > Nov > 09 > A/T - Whistling Noise When Hot Valve Body: Customer Interest A/T - Whistling Noise When Hot TSB 09-21-4 11/02/09 5R555 TRANSMISSION - WHISTLE NOISE WHEN HOT FORD: 2009-2010 Explorer Sport Trac, Explorer MERCURY: 2009-2010 Mountaineer This article supersedes TSB 09-12-5 to update the Service Procedure and Part List. ISSUE Some 2009-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 5R55S transmission may exhibit a high frequency whistle noise at idle in any gear position with the transmission fluid temperature at or above 170 degrees Fahrenheit (76 degrees Celsius). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install IDS/PDS or equivalent. 2. Verify that the transmission fluid temperature (TFT) PID is above 170 °F (76 °C). a. If it is not at 170 °F (76 °C), drive unit approximately 3 miles (5 Km) to reach temperature. b. If it is at 170 °F (76 °C), proceed to Step 3. 3. Return vehicle to idle and verify high frequency whistle noise is present in all gear selector positions (P-R-N-D-L). While Vehicle is at idle in park increase engine RPM by 150 to 200 RPM's the whistle noise will go away. a. If the above whistle condition can be verified in all gears proceed Step 4. b. If the whistle condition cannot be verified or is not present in all selector gear positions please follow the normal diagnostic routine procedures outlined in the Workshop Manual (WSM), Section 307-01. 4. Replace the main control separator plate following the WSM, Section 307-01A for Main Control Removal and Disassembly and Assembly of Subassemblies Main Control Valve Body. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 09-21-4 > Nov > 09 > A/T - Whistling Noise When Hot > Page 4115 NOTE VERIFY THE NEW REPLACEMENT SEPARATOR PLATE HAS TWO (2) ORIFICE LOCATIONS TO ASSURE YOU HAVE THE LATEST LEVEL. (FIGURES 1-2) 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 092104A 2009-2010 Explorer, 2.2 Hrs. Mountaineer, Explorer Sport Trac: Replace The Main Control Separator Plate And Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-4 > Nov > 09 > A/T Whistling Noise When Hot Valve Body: All Technical Service Bulletins A/T - Whistling Noise When Hot TSB 09-21-4 11/02/09 5R555 TRANSMISSION - WHISTLE NOISE WHEN HOT FORD: 2009-2010 Explorer Sport Trac, Explorer MERCURY: 2009-2010 Mountaineer This article supersedes TSB 09-12-5 to update the Service Procedure and Part List. ISSUE Some 2009-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 5R55S transmission may exhibit a high frequency whistle noise at idle in any gear position with the transmission fluid temperature at or above 170 degrees Fahrenheit (76 degrees Celsius). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install IDS/PDS or equivalent. 2. Verify that the transmission fluid temperature (TFT) PID is above 170 °F (76 °C). a. If it is not at 170 °F (76 °C), drive unit approximately 3 miles (5 Km) to reach temperature. b. If it is at 170 °F (76 °C), proceed to Step 3. 3. Return vehicle to idle and verify high frequency whistle noise is present in all gear selector positions (P-R-N-D-L). While Vehicle is at idle in park increase engine RPM by 150 to 200 RPM's the whistle noise will go away. a. If the above whistle condition can be verified in all gears proceed Step 4. b. If the whistle condition cannot be verified or is not present in all selector gear positions please follow the normal diagnostic routine procedures outlined in the Workshop Manual (WSM), Section 307-01. 4. Replace the main control separator plate following the WSM, Section 307-01A for Main Control Removal and Disassembly and Assembly of Subassemblies Main Control Valve Body. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-21-4 > Nov > 09 > A/T Whistling Noise When Hot > Page 4121 NOTE VERIFY THE NEW REPLACEMENT SEPARATOR PLATE HAS TWO (2) ORIFICE LOCATIONS TO ASSURE YOU HAVE THE LATEST LEVEL. (FIGURES 1-2) 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 092104A 2009-2010 Explorer, 2.2 Hrs. Mountaineer, Explorer Sport Trac: Replace The Main Control Separator Plate And Includes Time To Diagnose (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7Z490 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4127 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4128 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4134 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 4135 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4136 Valve Body: Locations 6R80 Transmission Mechatronic Assembly Item 3 - Check Ball Location Items 1-8 - Check Ball Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4137 NOTE: Note where the 8 check balls are located for reassembly. Item 2 - Check Ball Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4138 Valve Body: Diagrams 6R80 Transmission Mechatronic Assembly Mechatronic Mechatronic Upper Half Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4139 Mechatronic Lower Half Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4140 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4141 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4142 Check Ball Location Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S Valve Body: Service and Repair 5R55S Main Control Valve Body Main Control Valve Body Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4145 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. If equipped, remove the transmission fluid pan drain plug and drain the transmission fluid. 3. NOTE: Clean the area around the transmission vehicle harness connector to prevent contamination of the transmission control solenoid vehicle harness connector. Disconnect the transmission vehicle harness connector. 4. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan screws, transmission fluid pan and transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4146 5. Remove the transmission fluid filter. 6. Remove the reverse servo assembly screws and the reverse servo assembly. 7. Remove the transmission control solenoid body screws and the transmission control solenoid body. 8. Remove the manual control valve detent spring. 9. Remove the main control valve body screws and the main control valve body. Installation 1. Install the Valve Body Aligners into the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4147 2. Using the Valve Body Aligners, install the main control valve body and loosely install the main control valve body-to-case screws. 1. Install the short main control valve body-to-case screw. 2. Install the main control valve body-to-case screw with the larger head. 3. Install the remaining main control valve body-to-case screws. 3. Remove the Valve Body Aligners and loosely install the main control valve body screw. 4. Tighten the main control valve body screws in the sequence shown. - Tighten to 10 Nm (89 lb-in). 5. Install the manual control valve detent spring screw. - Tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4148 6. Install the reverse servo assembly. Tighten the reverse servo assembly screws in 2 stages, in the sequence shown. - Stage 1: Tighten to 5 Nm (44 lb-in). - Stage 2: Tighten to 11 Nm (97 lb-in). 7. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with transmission fluid. 8. NOTICE: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If it is damaged, transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in the sequence shown. - Tighten to 8 Nm (71 lb-in). 9. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid filter seals and install the transmission fluid filter. Tighten the transmission fluid filter screws. - Tighten to 10 Nm (89 lb-in). 10. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4149 reused. Install the transmission fluid pan gasket on the transmission fluid pan. 11. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan-to-case screws. 12. Tighten the transmission fluid pan-to-case screws in a crisscross sequence. - Tighten to 11 Nm (97 lb-in). 13. NOTICE: Damage will occur to the transmission vehicle harness connector if the screw is tightened above specification. NOTE: Always install new O-ring seals on the transmission control solenoid body connector. NOTE: Clean the area around the transmission vehicle harness connector to prevent contamination of the transmission control solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. Tighten to 5 Nm (44 lb-in). 14. Fill the transmission. For additional information, refer to Transmission Fluid Exchange See: Service and Repair/Procedures/5R55S/Transmission Fluid Exchange or Transmission Fluid Drain and Refill See: Service and Repair/Procedures/5R55S/Transmission Fluid Drain and Refill. Solenoid Body Assembly Solenoid Body Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4150 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transmission fluid pan drain plug and drain the transmission fluid. 3. NOTE: Clean the area around the transmission vehicle harness connector to prevent contamination of the transmission control solenoid vehicle harness connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4151 Disconnect the transmission vehicle harness connector. 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Remove the 16 transmission fluid pan-to-case screws, transmission fluid pan and transmission fluid pan gasket. 5. Remove the transmission fluid filter. 6. NOTICE: Do not damage the solenoid body connector pins. Remove the transmission control solenoid body screws and remove the transmission control solenoid body by pulling down on the transmission control solenoid body and pushing down on the transmission solenoid body connector from the other side of the case. Installation 1. Install new O-ring seals on the transmission control solenoid body connector. Lubricate the O-ring seals with transmission fluid. 2. NOTICE: Inspect the transmission case bore to make sure it is free of foreign material and not damaged. If damaged, a transmission leak may occur. Install the transmission control solenoid body. Tighten the transmission control solenoid body screws in sequence shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4152 - Tighten to 8 Nm (71 lb-in). 3. NOTICE: Damage may occur to transmission fluid filter seals if they are not lubricated with transmission fluid. NOTE: Make sure that the transmission fluid filter seals are correctly seated on the transmission fluid filter. Lubricate the transmission fluid seals and install the transmission fluid filter. - Tighten to 10 Nm (89 lb-in). 4. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the transmission fluid pan gasket should be reused. Install the transmission fluid pan and transmission fluid pan gasket and loosely install the transmission fluid pan-to-case screws. 5. Tighten the transmission fluid pan-to-case screws in a crisscross sequence. - Tighten to 11 Nm (97 lb-in). 6. NOTICE: Damage will occur to the transmission vehicle harness connector if the screw is tightened above specification. NOTE: Always install new O-ring seals on transmission control solenoid body harness connector. NOTE: Clean the area around the transmission vehicle harness connector to prevent contamination of the transmission control solenoid body connector. NOTE: Use petroleum jelly to lubricate the O-ring seals to aid in the installation process. Install and lubricate new O-ring seals on the transmission control solenoid body harness connector and connect the connector. Tighten to 5 Nm (44 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4153 7. Fill the transmission. For additional information, refer to Transmission Fluid Exchange See: Service and Repair/Procedures/5R55S/Transmission Fluid Exchange or Transmission Fluid Level Check See: Service and Repair/Procedures/5R55S/Transmission Fluid Level Check. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4154 Valve Body: Service and Repair 6R80 Mechatronic Assembly Removal Mechatronic assembly NOTICE: The only solenoid that is serviceable in the mechatronic assembly is Shift Solenoid E (SSE). If the mechatronic assembly is being removed due to a faulty SSE, follow the specific steps in this procedure to install a new SSE. If the mechatronic assembly is being removed due to a faulty solenoid other than SSE, a new mechatronic assembly must be installed. NOTE: If a new or existing mechatronic assembly is installed, the Transmission Control Module (TCM) will need to be flashed with the latest calibration level. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTICE: 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 transmission fluid fill plug transmission fluid level indicator assembly located on the passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will relieve any vacuum that might have built up in the transmission. This will aid in allowing the transmission fluid pan to be easily removed when the bolts are removed. 4. Remove the transmission fluid pan and allow the transmission fluid to drain. 5. Remove the transmission fluid pan gasket. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4155 6. Remove and discard the transmission fluid filter. 7. Pull the release tab and pull down on the bulkhead connector retainer. 8. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission vehicle harness connector. Electrostatic discharge may occur and may cause damage to the mechatronic unit. With the release tab down, pull the outer shell of the transmission vehicle harness connector out of the mechatronic assembly. 9. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission vehicle harness connector. Electrostatic discharge may occur and may cause damage to the mechatronic unit. Pull the transmission vehicle harness connector out of the transmission. 10. NOTICE: During removal of the mechatronic assembly, the thermal bypass valve will fall out of the transmission case. Damage to the valve will occur if the valve falls out. Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly and the bypass valve. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4156 Shift Solenoid E (SSE) 11. Remove the 6 long bolts from the TCM unit. 12. Carefully separate the TCM from the mechatronic assembly. 1. TCM 2. Mechatronic assembly 13. Remove the 8 solenoid bracket bolts and the solenoid bracket. 14. Remove Shift Solenoid E (SSE). Installation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4157 SSE 1. Install SSE. 2. Position the solenoid bracket in place and install the 8 bolts. - Tighten to 6 Nm (53 lb-in). 3. Position the TCM on the mechatronic assembly. 1. TCM 2. Mechatronic assembly 4. Install the 6 long bolts into the TCM unit. Tighten the bolts in the sequence shown. - Tighten to 6 Nm (53 lb-in). Mechatronic assembly 5. 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 tubes 2. Green feed tube 3. Blue feed tube Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4158 6. Verify the rubber adapter is in place. 7. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal bypass valve in the transmission case. 8. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission vehicle harness connector. 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. 9. Tighten the mechatronic bolts in the sequence shown. - Tighten to 8 Nm (71 lb-in). 10. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission vehicle harness connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4159 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 transmission vehicle harness connector into the transmission. Make sure that the transmission vehicle harness connector is fully seated into the mechatronic assembly. 11. Press up on the tab and lock the outer shell of the transmission vehicle harness electrical connector in place. Make sure that the locking tab is securely locked. 12. Install a new transmission fluid filter. 13. NOTE: The transmission fluid pan gasket can be reused if not damaged. Install a new transmission fluid pan gasket, if required. 14. Install the transmission fluid pan and tighten the transmission fluid pan bolts in a crisscross pattern. - Tighten to 12 Nm (106 lb-in). 15. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 5R55S > Page 4160 16. Make sure the transmission fluid is at the correct level, follow the steps for Adding Additional Transmission Fluid or Removing Transmission Fluid. For additional information, refer to Transmission Fluid Drain and Refill See: Service and Repair/Procedures/6R80/Transmission Fluid Drain and Refill. 17. If a new or existing mechatronic assembly is installed, the TCM will need to be flashed with the latest calibration. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 11-3-25 > Mar > 11 > A/T Fluid Leaks From Bulkhead Connector Wiring Harness: Customer Interest A/T - Fluid Leaks From Bulkhead Connector TSB 11-3-25 03/31/11 6R80 TRANSMISSION BULKHEAD CONNECTOR SLEEVE LEAKING TRANSMISSION FLUID FORD: 2009-2010 Expedition, Explorer Sport Trac, Explorer, F-150 LINCOLN: 2009-2010 Navigator MERCURY: 2009-2010 Mountaineer ISSUE Some 2009-2010 F-150, Expedition, Explorer Sport Trac, Explorer, Mountaineer and Navigator vehicles equipped with a 6R80 transmission may show signs of transmission fluid leakage around the transmission bulkhead connector sleeve. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Verify the leak is present at the transmission bulkhead connector sleeve. With the vehicle in neutral, position it on a hoist. For additional information, refer to Workshop Manual (WSM), Section 100-02. 1. Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling back on the connector. 2. Remove the transmission fluid pan and allow the transmission fluid to drain. 3. Pull the release tab and pull down on the transmission bulkhead electrical connector retainer. 4. With the release tab down, pull the connector sleeve out of the case/mechatronic assembly. 5. Lube new connector sleeve 0-rings with clean transmission fluid, then install connector sleeve into case/mechantronic assembly. 6. Press up on the tab and lock the outer shell of the transmission bulkhead electrical connector sleeve in place. Make sure that the locking tab is securely locked. 7. Install the transmission fluid pan/gasket and refill transmission fluid refer to WSM, Section 307-01 for refill procedure. NOTE DO NOT TOUCH THE ELECTRICAL CONNECTOR PINS OR THE EXPOSED SOLENOID TABS ON THE TRANSMISSION BULKHEAD ELECTRICAL CONNECTOR. ELECTROSTATIC DISCHARGE MAY OCCUR AND MAY CAUSE DAMAGE TO THE TRANSMISSION CONTROL MODULE (TCM). NOTE BULKHEAD CONNECTOR SLEEVES MAY COME WITH RED OR BLACK 0-RING SEALS. USE ONLY BULKHEAD CONNECTOR SLEEVE THAT HAS BLACK 0-RING SEAL FOR THIS 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 11-3-25 > Mar > 11 > A/T Fluid Leaks From Bulkhead Connector > Page 4169 OPERATION DESCRIPTION TIME 110325A 2009-2010 Explorer, 1.7 Hrs. Mountaineer, Explorer Sport Trac, And F-150: Replace Connector Sleeve Includes Time To Remove And Install Transmission Fluid Pan (Do Not Use With Any Other Labor Operations) 110325A 2009-2010 Expedition And 1.8 Hrs. Navigator: Replace Connector Sleeve Includes Time To Remove And Install Transmission Fluid Pan (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G276 D8 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4174 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 (V6-4.0L (2009)) 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: > 11-3-25 > Mar > 11 > A/T - Fluid Leaks From Bulkhead Connector Wiring Harness: All Technical Service Bulletins A/T - Fluid Leaks From Bulkhead Connector TSB 11-3-25 03/31/11 6R80 TRANSMISSION BULKHEAD CONNECTOR SLEEVE LEAKING TRANSMISSION FLUID FORD: 2009-2010 Expedition, Explorer Sport Trac, Explorer, F-150 LINCOLN: 2009-2010 Navigator MERCURY: 2009-2010 Mountaineer ISSUE Some 2009-2010 F-150, Expedition, Explorer Sport Trac, Explorer, Mountaineer and Navigator vehicles equipped with a 6R80 transmission may show signs of transmission fluid leakage around the transmission bulkhead connector sleeve. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Verify the leak is present at the transmission bulkhead connector sleeve. With the vehicle in neutral, position it on a hoist. For additional information, refer to Workshop Manual (WSM), Section 100-02. 1. Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling back on the connector. 2. Remove the transmission fluid pan and allow the transmission fluid to drain. 3. Pull the release tab and pull down on the transmission bulkhead electrical connector retainer. 4. With the release tab down, pull the connector sleeve out of the case/mechatronic assembly. 5. Lube new connector sleeve 0-rings with clean transmission fluid, then install connector sleeve into case/mechantronic assembly. 6. Press up on the tab and lock the outer shell of the transmission bulkhead electrical connector sleeve in place. Make sure that the locking tab is securely locked. 7. Install the transmission fluid pan/gasket and refill transmission fluid refer to WSM, Section 307-01 for refill procedure. NOTE DO NOT TOUCH THE ELECTRICAL CONNECTOR PINS OR THE EXPOSED SOLENOID TABS ON THE TRANSMISSION BULKHEAD ELECTRICAL CONNECTOR. ELECTROSTATIC DISCHARGE MAY OCCUR AND MAY CAUSE DAMAGE TO THE TRANSMISSION CONTROL MODULE (TCM). NOTE BULKHEAD CONNECTOR SLEEVES MAY COME WITH RED OR BLACK 0-RING SEALS. USE ONLY BULKHEAD CONNECTOR SLEEVE THAT HAS BLACK 0-RING SEAL FOR THIS 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 11-3-25 > Mar > 11 > A/T - Fluid Leaks From Bulkhead Connector > Page 4180 OPERATION DESCRIPTION TIME 110325A 2009-2010 Explorer, 1.7 Hrs. Mountaineer, Explorer Sport Trac, And F-150: Replace Connector Sleeve Includes Time To Remove And Install Transmission Fluid Pan (Do Not Use With Any Other Labor Operations) 110325A 2009-2010 Expedition And 1.8 Hrs. Navigator: Replace Connector Sleeve Includes Time To Remove And Install Transmission Fluid Pan (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 7G276 D8 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4185 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4195 Fluid - Differential: Fluid Type Specifications Front Differential Front Differential Dana 30.............................................................................................................................................M otorcraft SAE 80W-90 Premium Rear Axle Lubricant Part Number......................................................................................................................................... ..XY-80W90-QL(US) / CXY-80W90-1L(CANADA) Specification......................................................................................................................................... .........................................................WSP-M2C197-A Rear Differential Rear Differential Ford 8.8 Inch Ring Gear.................................................................................................................Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant Part Number......................................................................................................................................X Y-75W-140-QL(US) / CXY-75W140-1L(CANADA) Specification......................................................................................................................................... ........................................WSL-M2C192-A and GL-5 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4201 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 Bearing Cup Remover and Slide Hammer, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1. Firmly engage the tangs of the Bearing Cup Remover on the stub shaft pilot bearing. 2. Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. Installation 1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing. 2. NOTICE: 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 Halfshaft Pilot Bearing Installer and Handle. 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 LIS17850 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 (V6-4.0L (2009)) 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 4202 6. Install the halfshaft assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4203 Differential Output Shaft Bearing: Service and Repair Front Drive Axle/Differential - Dana 30 Stub Shaft Pilot Bearing and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4204 Removal Both sides 1. Remove the halfshafts. Right side 2. Remove the axle shaft. Both sides 3. Using the Converter Oil Seal Remover and a Slide Hammer, remove the stub shaft oil seals. 4. Using the Bearing Remover and a Slide Hammer, remove the stub shaft pilot bearings. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4205 5. Clean the bearing and seal surfaces of any foreign material. Installation Right side 1. Using the Handle and Axle Bearing Replacer (RH), install the stub shaft pilot bearing. 2. Using the Handle and Axle Seal Replacer, install the stub shaft oil seals. 3. Install the axle shaft. Left side 4. Using the Handle and Front Axle Bearing Installer (LH), install the stub shaft bearing. 5. Using the Handle and Axle Seal Replacer, install the stub shaft seal. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4206 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 (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4211 Removal 1. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer kit or damage to the component may occur. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel brake disc. 3. Remove the rear driveshaft. 4. Install a Nm (lb-in) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation or damage to the component may occur. 5. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the pinion nut. 6. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation. 7. Using the 2-Jaw Puller, remove the pinion flange. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4212 8. 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. NOTE: If the drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. If the drive pinion seal was removed, use the Drive Pinion Oil Seal Installer 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 Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer, install the pinion flange. 7. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4213 installation or damage to the component may occur. Select the new pinion nut for installation. Install and hand-tighten the pinion nut. 8. NOTICE: 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 or component damage may occur. Install the new pinion nut that is included in the collapsible spacer kit. Tighten the new 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 (lb-in) torque wrench. - Rotational torque must be at least the recorded original torque plus a maximum of 5 lb-in. 9. Install the rear brake disc. 10. Install the rear driveshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4214 Pinion Flange: Service and Repair Front Drive Axle/Differential - Dana 30 Drive Pinion Flange and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4215 Removal NOTE: 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. 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. NOTICE: When removing the disc brake caliper, never allow it to hang from the brake hose or damage to the component may occur. Remove the 4 disc brake caliper anchor bolts, then remove the disc brake calipers and disc brake caliper anchors as an assembly. - Using mechanic's wire, position and support the disc brake calipers and disc brake caliper anchors. 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 Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the pinion nut. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4216 8. Using the 2-Jaw Puller, 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4217 Using the Drive Pinion Oil Seal Installer, install the drive pinion oil seal. 4. NOTICE: Never install the pinion flange with power tools or damage to the component may occur. 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. NOTICE: 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 or damage to the component may occur. Using the Drive Pinion Flange Holding Fixture 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 lb-in) more than the initial reading taken during removal. 7. Install the disc brake calipers and disc brake caliper anchors as an assembly, then the 4 disc brake caliper anchor bolts. - Tighten to 108 Nm (80 lb-ft). 8. NOTICE: Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft may pinch the boot between the shaft and the flange and cause the boot to tear. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4218 NOTE: Install the driveshaft with new bolts and washers and new bolts and U-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 (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4223 Removal 1. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion bearing preload reduction, install the nut supplied with the new spacer kit or damage to the component may occur. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear wheel brake disc. 3. Remove the rear driveshaft. 4. Install a Nm (lb-in) torque wrench on the pinion nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for installation or damage to the component may occur. 5. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the pinion nut. 6. Index-mark the pinion flange and drive pinion gear to maintain initial balance during installation. 7. Using the 2-Jaw Puller, remove the pinion flange. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4224 8. 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. NOTE: If the drive pinion seal becomes misaligned during installation, remove the drive pinion seal and install a new drive pinion seal. If the drive pinion seal was removed, use the Drive Pinion Oil Seal Installer 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 Drive Pinion Flange Holding Fixture and Drive Pinion Flange Installer, install the pinion flange. 7. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color new drive pinion nut for Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4225 installation or damage to the component may occur. Select the new pinion nut for installation. Install and hand-tighten the pinion nut. 8. NOTICE: 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 or component damage may occur. Install the new pinion nut that is included in the collapsible spacer kit. Tighten the new 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 (lb-in) torque wrench. - Rotational torque must be at least the recorded original torque plus a maximum of 5 lb-in. 9. Install the rear brake disc. 10. Install the rear driveshaft. Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4226 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 Bearing Cup Remover and Slide Hammer, remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. 1. Firmly engage the tangs of the Bearing Cup Remover on the stub shaft pilot bearing. 2. Remove the stub shaft pilot bearing and stub shaft pilot bearing oil seal. Installation 1. Using rear axle lubricant, lubricate the new stub shaft pilot bearing. 2. NOTICE: 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 Halfshaft Pilot Bearing Installer and Handle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4227 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 LIS17850 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. 6. Install the halfshaft assembly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4228 Seals and Gaskets: Service and Repair Front Drive Axle/Differential - Dana 30 Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4229 Removal Both sides 1. Remove the halfshafts. Right side 2. Remove the axle shaft. Both sides 3. Using the Converter Oil Seal Remover and a Slide Hammer, remove the stub shaft oil seals. 4. Using the Bearing Remover and a Slide Hammer, remove the stub shaft pilot bearings. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4230 5. Clean the bearing and seal surfaces of any foreign material. Installation Right side 1. Using the Handle and Axle Bearing Replacer (RH), install the stub shaft pilot bearing. 2. Using the Handle and Axle Seal Replacer, install the stub shaft oil seals. 3. Install the axle shaft. Left side 4. Using the Handle and Front Axle Bearing Installer (LH), install the stub shaft bearing. 5. Using the Handle and Axle Seal Replacer, install the stub shaft seal. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4231 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 (V6-4.0L (2009)) 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 4232 Removal NOTE: 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. 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. NOTICE: When removing the disc brake caliper, never allow it to hang from the brake hose or damage to the component may occur. Remove the 4 disc brake caliper anchor bolts, then remove the disc brake calipers and disc brake caliper anchors as an assembly. - Using mechanic's wire, position and support the disc brake calipers and disc brake caliper anchors. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4233 7. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the pinion nut. 8. Using the 2-Jaw Puller, 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4234 3. NOTE: Lubricate the drive pinion oil seal lips with axle lubricant. Using the Drive Pinion Oil Seal Installer, install the drive pinion oil seal. 4. NOTICE: Never install the pinion flange with power tools or damage to the component may occur. 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. NOTICE: 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 or damage to the component may occur. Using the Drive Pinion Flange Holding Fixture 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 lb-in) more than the initial reading taken during removal. 7. Install the disc brake calipers and disc brake caliper anchors as an assembly, then the 4 disc brake caliper anchor bolts. - Tighten to 108 Nm (80 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4235 8. NOTICE: Always connect the front driveshaft to the axle first. Otherwise, the weight of the driveshaft may pinch the boot between the shaft and the flange and cause the boot to tear. NOTE: Install the driveshaft with new bolts and washers and new bolts and U-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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Front Drive Halfshafts Axle Shaft Assembly: Specifications Front Drive Halfshafts General Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Specifications > Front Drive Halfshafts > Page 4241 Axle Shaft Assembly: Specifications Rear Drive Halfshafts General Specifications Material Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 The front axle halfshafts consist of the following: - Inner CV joints - Outer CV joints - Interconnecting shafts - A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together - A circlip that retains the splined inboard CV joint to the differential side gear on the LH halfshaft - A circlip that retains the splined RH inboard CV joint to the intermediate shaft - CV joint boot clamps - Convoluted CV joint boots - Tripod joint housings - Ball and cage housings The front axle halfshafts are driven by the differential side gears inside the front axle assembly or the RH axle shaft. Rotational torque is transferred from the stub shafts through the inner CV joint, intermediate shaft and outer CV joint to the outer stub shaft. The outboard stub shafts are splined to drive the wheel hubs. They are retained in the wheel hubs by special wheel hub nuts, which also control the wheel bearing preload. The LH halfshaft is splined on the inboard stub shaft and is retained in the differential side gear in the transaxle by a circlip. The RH halfshaft has internal splines which are driven by the axle shaft. The axle shaft has a circlip on the outboard end and is retained inside the inboard stub shaft. New circlips must be installed whenever they are removed. The CV joint mates the interconnecting shaft with the stub shaft. The joint allows for smooth rotation of the interconnecting shaft and the stub shafts. They also adjust for length variances and angle requirements as the vehicle goes through jounce and rebound. New halfshaft components are available as kits containing grease, boots and clamps. Handle all halfshaft components carefully during removal and installation and during various component disassembly and assembly procedures. Never pick up or hold the halfshaft only by the inboard or outboard CV joint. 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 from the front hub. 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 only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint housing only. Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. Do not remove the outer CV joint by pulling on the interconnecting shaft. Inspect all machined surfaces and splines for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Front Drive Halfshafts > Page 4244 Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts Rear Drive Halfshafts The rear drive halfshafts consist of the following: - Inner CV joints - Outer CV joints - Interconnecting shafts - Convoluted CV joint boots - CV joint boot clamps - Special CV high-temperature grease - Tripod joint housings - Ball and cage housings - A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together - A circlip that retains the splined inboard CV joint to the differential side gear - The RH and LH halfshafts are different lengths, with the LH halfshaft being the longer of the 2. The rear drive halfshafts link the rear axle to the rear wheel hubs. The CV joints allow the halfshafts to rotate smoothly through the required changes in angles between the stationary axle and the varying angles of the rear wheels including jounce and rebound. The CV joints are either tri-lobed style or the caged ball type depending on inboard or outboard. New halfshaft components are available as kits containing grease, boots and clamps. Handle all halfshaft components carefully during removal and installation and during various component disassembly and assembly procedures. Never pick up or hold the halfshaft only by the inboard or outboard CV joint. 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 from the hub. 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 only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint housing only. Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. Do not remove the outer CV joint by pulling on the interconnecting shaft. Inspect all machined surfaces and splines for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Description and Operation > Page 4245 Axle Shaft Assembly: Testing and Inspection Driveline System Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Driveline or GO to Symptom Chart - NVH. See: Differential Assembly/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Chart Driveline See: Differential Assembly/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Chart - NVH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4248 Removal and Installation Both halfshafts 1. NOTICE: 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. 2. Remove the front wheel and tire. 3. Remove and discard the halfshaft nut. - To install, tighten to 250 Nm (184 lb-ft). 4. NOTICE: 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 lb-ft). 5. NOTICE: Do not use a hammer to separate the outboard Constant Velocity (CV) joint from the hub. Damage to the threads and internal CV joint components can result. Using the Front Wheel Hub Remover, press the outboard CV joint until it is loose in the hub. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4249 6. Remove and discard the tie-rod nut. - To install, tighten the new nut to 103 Nm (76 lb-ft). 7. Using the C-Frame and Screw, separate the tie rod from the knuckle. 8. Remove and discard the stabilizer bar link nut. - To install, tighten the new nut and grommet to 35 Nm (26 lb-ft). 9. Remove and discard the upper ball joint nut. - To install, tighten the new nut to 55 Nm (41 lb-ft). 10. NOTE: 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 Steering Arm Remover, disconnect the upper ball joint from the knuckle. LH halfshaft 11. NOTICE: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard Constant Velocity (CV) joint housing. Using the Halfshaft Remover, disengage the LH CV joint housing from the side gear. 12. Remove the LH halfshaft. RH halfshaft 13. NOTE: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4250 14. Remove the RH halfshaft. Both halfshafts 15. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4251 Removal and Installation 1. NOTICE: 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. 2. Remove the rear wheel and tire. 3. Remove the halfshaft nut. - To install, tighten to 275 Nm (203 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4252 4. NOTICE: 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. Using the Front Wheel Hub Remover, 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 (177 lb-in). 6. Remove and discard the outboard toe link nut and back out the bolt for clearance. - To install, tighten to 350 Nm (259 lb-ft) at curb ride height. 7. Remove and discard the lower arm outboard bolt. - To install, tighten to 275 Nm (203 lb-ft) at curb ride height. 8. Remove and discard the 3 wheel knuckle bolts. - To install, tighten to 275 Nm (203 lb-ft). 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 lb-ft) at curb ride height. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4253 10. Using the Halfshaft Remover and Handle, disengage the inboard CV joint housing from the differential side gear. 11. Remove the halfshaft assembly. 12. NOTICE: Do not tighten the 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. NOTE: Apply the brake to keep the halfshaft from rotating. Position the halfshaft in the hub and use the previously removed hub nut to seat the halfshaft. - Tighten to 350 Nm (258 lb-ft). - Remove and discard the hub nut. 13. NOTICE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur. NOTE: Apply the brake to keep the halfshaft from rotating. Install a new hub nut. - Tighten to 350 Nm (258 lb-ft). 14. NOTE: Always install a new differential stub shaft seal whenever the halfshaft is removed. NOTE: Make sure the halfshaft is completely seated in the differential side gear by pushing the halfshaft into the rear axle assembly until an audible click is heard or a leak may occur from the axle assembly. NOTE: Apply the brake to keep the halfshaft from rotating. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4254 Axle Shaft Assembly: Overhaul Front Drive Halfshafts Halfshaft Disassembly 1. Remove the RH or LH halfshaft assembly. For additional information, refer to Halfshaft See: Removal and Replacement/Front Drive Halfshafts. 2. For the inboard CV joint, carry out the following: 1. Remove and discard the 2 boot clamps. 2. Remove the inboard CV joint housing. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4255 3. For the inboard CV joint, carry out the following: 1. Remove and discard the retainer circlip. 2. Slide the boot away from the CV joint. 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, carry out the following: 1. Remove and discard the 2 boot clamps. 2. Remove and discard the boot. Assembly 1. Lubricate the outboard CV joint. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4256 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. 2. Position the boot so the rib on the boot is located in the groove of the shaft. 3. Position the outboard halfshaft boot and the outboard boot clamps. 1. Position the boot. 2. Position the 2 boot clamps. 4. Using the Constant Velocity (CV) Joint Boot Clamp Installer, install the outboard CV boot clamps. 5. Position the inboard clamp and boot. 6. Install the CV joint and snap ring on the halfshaft. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4257 7. Install the stop ring. 8. 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. 9. Position the CV housing on the CV joint. 10. Position the inboard halfshaft boot and clamp. 1. Position the boot in the housing groove. 2. Position the boot clamp. 11. Set the halfshaft assembled length to specifications. For additional information, refer 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4258 12. Using the Constant Velocity (CV) Joint Boot Clamp Installer, install the boot clamps. 13. Install the RH or LH halfshaft assembly. For additional information, refer to Halfshaft See: Removal and Replacement/Front Drive Halfshafts. Rear Drive Halfshafts Halfshaft Joint Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4259 Disassembly 1. Remove the halfshaft assembly. For additional information, refer to Halfshaft See: Removal and Replacement/Rear Drive Halfshafts. 2. For the inboard CV joint, carry out the following: 1. Remove and discard the boot clamps. 2. Remove the inboard CV joint housing. 3. For the inboard CV joint, carry out the following: 1. Remove and discard the retainer circlip. 2. Slide the boot away from the CV joint. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4260 4. Using a suitable 3-jaw puller, remove the CV joint. 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, carry out the following: 1. Remove and discard the boot clamps. 2. Remove and discard the boot. Assembly 1. For the outboard CV joint, carry out the following: 1. Slide the boot on the interconnecting shaft. 2. Pack the outboard CV joint with 225 g (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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4261 2. Using the Constant Velocity Joint Boot Clamp Installer, install the boot clamps. 3. NOTE: Install a new circlip every time the halfshaft is removed from the axle. Install a new retainer circlip. 4. For the inboard CV joint, carry out the following: 1. Position the clamp on the interconnecting shaft. 2. Position the boot on the interconnecting shaft. 3. Install the tri-lobe insert. 5. Using the Drive Pinion Oil Seal Installer, install the CV joint. 6. Install the retainer circlip. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Component Information > Service and Repair > Removal and Replacement > Page 4262 7. For the inboard CV joint, carry out the following: 1. Pack the inboard CV joint housing with 250 g (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. 8. Set the halfshaft assembled length to specifications. For additional information, refer 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. 9. Using the Constant Velocity Joint Boot Clamp Installer, install both boot clamps. 10. Install the halfshaft assembly. For additional information, refer to Halfshaft See: Removal and Replacement/Rear Drive Halfshafts. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4267 2. Remove and discard the halfshaft nut. - To install, tighten the new nut to 250 Nm (184 lb-ft). 3. Using the Front Wheel Hub Remover, separate the outboard CV joint from the wheel hub. 4. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 bolts and the wheel bearing and hub assembly. - Discard the bolts. - To install, tighten the new bolts to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4268 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. 2. Remove the 3 brake disc shield bolts. - To install, tighten to 8 Nm (71 lb-in). 3. Using the Bearing Puller and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4269 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. For additional information, refer to Wheel Knuckle See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft nut....................................................................................................................... ........................................................................250 Nm (184 lb-ft) Rear Drive Halfshaft nut....................................................................................................................... ........................................................................275 Nm (203 lb-ft) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 CV joint flanges are not serviced. If the driveshaft center bearing is worn or damaged, install a new driveshaft. 1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear, Two-Piece, Four Wheel Drive (4WD) See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft - Rear, Two-Piece or Driveshaft Rear, Two-Piece, Rear Wheel Drive (RWD) See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft - Rear, Two-Piece. 2. NOTICE: Do not clamp the driveshaft tube in a vise. Denting or localized fracturing may result causing driveshaft failure during vehicle operation. Position the center U-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 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 4278 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Description and Operation Drive/Propeller Shaft: Description and Operation Driveshaft The driveshafts consist of the following: - U-joint flanges - U-joints - Nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearings and improve grease movement - Lubed-for-life design and require no lubrication - CV joint flanges - CV joints - Slip-yoke - Slip-joint boots - Traditional welded-on balance weights Vehicles have the following types of driveshafts: - One-piece rear driveshaft with 2 U-joints and a front slip-yoke - One-piece front driveshaft with a front U-joint, a slip-yoke and a rear CV joint - Two-piece rear driveshaft with 3 U-joints - Two-piece rear driveshaft with 2 CV joints and one U-joint NOTE: Whenever the vehicle is raised on a hoist, inspect the U-joint slip-yoke boot for rips or holes. Install new if required. NOTE: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and U-joints to prevent application of any undercoating material. The driveshaft transfers input from the transmission or transfer case to the front or rear drive axles. The driveshaft is composed of the U-joints or CV joints, connecting shafts and attaching yokes. The driveshaft accommodates the change in length in the driveline system by sliding on the transmission output shaft with a slip-yoke or a slip-joint which is integral to the driveshaft. The shafts vary in diameter, length, number of coupling shafts and U-joints or CV joints, depending on vehicle application. The U-joints and CV joints allow the driveshaft to rotate smoothly through the changing angles between the transmission output shaft and the driveshaft, plus the changes between the rear axle pinion angle and the driveshaft. On 2-wheel drive vehicles, power is transmitted through the transmission to the driveshaft and then to the rear axle. On All-Wheel Drive (AWD) vehicles, power is transmitted from the transmission to the front and rear axles through the transfer case. The engine angle is built into the engine mounts. If the driveshaft angles are out of specification, the engine mounts must be inspected for damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures Drive/Propeller Shaft: Procedures Driveline Angle Measurement Driveline Angle Measurement NOTE: This procedure does not apply to CV joints, flex couplers or double cardan joints that are used in some driveshafts. This check is for single-cross and roller-style joints found in the driveshafts. NOTE: Prior to checking driveline angularity, inspect the U-joints for correct operation. NOTE: An incorrect driveline angle can cause a vibration or shudder. NOTE: Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the rear axle pinion. Factors determining driveline angularity include ride height, rear spring and engine mounts. All vehicles 1. Carry out the following preliminary setup steps: - Inspect the U-joints for correct operation. - Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end alignment rack. - Verify the curb position ride height is within specifications with the vehicle unloaded and all of the tires are inflated to their normal operating pressures. - Calibrate the Anglemaster II Driveline Inclinometer/Protractor by placing it on a clean, flat level of the frame rail and press the ALT-ZERO button. Vehicles with flat-flanged, split-pin or slip-flanged U-joints 2. NOTE: If equipped, remove the snap ring to allow access to the base of the U-joint cup. Make sure the Anglemaster II Driveline Inclinometer/Protractor is seated against the U-joint cup. NOTE: Rotate the driveshaft until the flange U-joint cup is parallel with the floor. This will simplify taking measurements. To check the U-joint operating angle, install the Anglemaster II Driveline Inclinometer/Protractor. Check and record the flange angle as angle A. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4284 3. Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the connecting component. Record the measurement of the component angle as angle B. Multiple piece driveshafts 4. NOTE: Repeat this step for each center support bearing on the driveshaft. NOTE: It is not necessary to remove the U-joint snap ring, if equipped, for these measurements. Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the components in front and behind the center support bearing U-joint in the area indicated. Record the front component as angle A and the rear component as angle B. All vehicles 5. NOTE: When 2 connected components slope in the same direction, subtract the smallest number from the larger number to find the U-joint operating angle. When 2 connected components slope in the opposite direction, add the measurements to find the U-joint operating angle. Calculate the difference in the slope of the components to determine the U-joint operating angle. - The U-joint operating angle is the angle formed by 2 yokes connected by a cross and bearing kit. Ideally, the operating angles on each connection of the driveshaft must: be equal or within one degree of each other. - have a 3 degree maximum operating angle. - have at least one-half of one degree continuous operating angle. 6. If the angle is not within specifications, repair or adjust to obtain the correct angle. Inspect the engine mounts, transmission mounts, center support bearing mounting, rear suspension, rear axle, rear axle mounting or the frame for wear or damage. Driveshaft Runout and Balancing Driveshaft Runout and Balancing Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4285 Driveshaft Inspection NOTE: Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake. Driveline vibration is directly related to the speed of the vehicle and is noticed at various speeds. Driveline vibration can be perceived as a tremor in the floorpan or heard as a rumble, hum or boom. NOTE: Refer to Specifications for all runout specifications. 1. NOTE: Do not make any adjustments before carrying out a road test. Do not change the tire pressure or the vehicle load. Carry out a visual inspection of the vehicle. Operate the vehicle and verify the condition by reproducing it during the road test. - The concern should be directly related to vehicle road speed, not affected by acceleration or deceleration or could not be reduced by coasting in NEUTRAL. 2. With the vehicle in NEUTRAL, position it on a hoist. - The driveshaft should be kept at an angle equal to or close to the curb-weighted position. Use a twin-post hoist or a frame hoist with jackstands. 3. Inspect the driveshaft for damage, undercoating or incorrectly seated U-joints. Rotate the driveshaft slowly by hand and feel for binding or end play in the U-joint trunnions. Remove the driveshaft. Inspect the slip yoke splines for any galling, dirt, rust or incorrect lubrication. Clean the driveshaft or install new U-joints as necessary. Install a new driveshaft if damaged. After any corrections or new components are installed, recheck for the vibration at the road test speed. If the vibration is gone, test drive the vehicle. - If the vibration persists or the driveshaft passes visual inspection, measure the driveshaft runout. Driveshaft Runout 1. Install the Dial Indicator Gauge with Holding Fixture. Rotate the driveshaft by turning the axle and measure the runout at the front, the center and the rear of the driveshaft. If the runout exceeds 1 mm (0.040 in) at the front or center, install a new driveshaft. - If the front and center is within 1 mm (0.040 in), but the rear runout is not, index-mark the rear runout high point and proceed to Step 2. - If the runout is within 1 mm (0.040 in) at all points, recheck for vibration at road test speed. If the vibration persists, balance the driveshaft. For additional information, refer to Driveshaft Balancing in this procedure. 2. NOTE: Circular pinion flanges can be turned in 90 degree or one-fourth increments. Half-round pinion flanges are limited to 2 positions. Index-mark the driveshaft to the pinion flange. Disconnect the driveshaft and rotate it 180 degrees. Reconnect the driveshaft. Recheck the runout at the rear of the driveshaft. - If the runout is still over specification, mark the high point and proceed to Step 3. - If the runout is within specification, check for the vibration at the road test speed. If the vibration is still present, balance the driveshaft. For additional information, refer to Driveshaft Balancing in this procedure. 3. Excessive driveshaft runout can originate in the driveshaft itself or from the pinion flange. To find the source, compare the 2 high points previously determined. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4286 - If the index marks are close together, within 25 mm (1 in), the driveshaft is eccentric. Install a new driveshaft. - If the marks are on opposite sides of the driveshaft, 180 degrees apart, the slip yoke or pinion flange is responsible. Check the pinion flange runout. If the pinion flange runout exceeds specifications, a bent pinion is indicated. - If the pinion flange and pinion runouts are within specifications, road test and check for the vibration at the road test speed. If the vibration persists, balance the driveshaft. For additional information, refer to Driveshaft Balancing in this procedure. Driveshaft Balancing - Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) All vehicles 1. Install the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) to the vehicle. 2. Working under the vehicle, install an accelerometer. The accelerometer can be attached and mounted near either the transmission or differential end of the driveshaft. 3. Clean an area of the driveshaft and install the reflective tape, then install the photo-tachometer sensor. The sensor should be placed at approximately a 20-degree angle from perpendicular to the surface of the reflective tape. Make sure the sensor does not get moved during the balance procedure. 1. Reflective tape. 2. Photo-tachometer sensor. 4. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a driveshaft balance test with the driveshaft unmodified. Vehicles with tapped pinion flanges 5. Label the tapped holes in the pinion flange numerically, starting at the top hole as 1. Mark the remaining holes 2, 3 and 4. Label in the direction of rotation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4287 6. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a second test with the 12 mm (0.47 in) test weight set screw in the No. 1 hole, previously marked on the pinion flange. 7. Remove the test weight, then install the weight combination directed by the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Vehicles without tapped pinion flanges 8. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a second test with a test weight. Using a metal band, secure the test weight to the end of the driveshaft. The weight should be placed at the end of the driveshaft tube, as close to the tube-to-yoke weld seam as possible. Mark the location of the test weight on the driveshaft, as shown in the figure below. 1. Test weight. 2. Tube-to-yoke weld seam. 3. Driveshaft pinion flange. - Select the test weight based on driveshaft size. Larger driveshafts use 10 g (0.353 oz). Smaller driveshafts use 5 g (0.176 oz). 9. Remove the test weight, then install the recommended weight at the position directed by the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Using a metal band and epoxy, secure the test weight to the driveshaft, as shown in the figure below. 1. Test weight. 2. Measure in this direction. 3. Driveshaft diameter. 4. Directional rotation. 5. Balance weight relative to test weight centerline. - The results are displayed with respect to the location to where the test weight was placed. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4288 All vehicles 10. Using the Mastertech(R) Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a third test to verify the repair. Driveshaft Balancing - Hose Clamp Method 1. Install 1 or 2 hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be determined through trial and error. 2. Mark the rear of the driveshaft into 4 approximately equal sectors and number the marks 1 through 4. Install a hose clamp on the driveshaft with its head at position No. 1, as shown in the figure below. Check for vibration at road speed. Recheck with the clamp at each of the other positions to find the position that shows minimum vibration. If 2 adjacent positions show equal improvement, position the clamp head between them. 3. If the vibration persists, add a second clamp at the same position and recheck for vibration. 4. If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best position determined in Step 2. Separate the clamp heads about 13 mm (1/2 in) and recheck for vibration at the road speed. 5. Repeat the process with increasing separation until the best combination is found or the vibration is reduced to an acceptable level. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4289 Drive/Propeller Shaft: Removal and Replacement Driveshaft - Front Driveshaft - Front Removal and Installation NOTICE: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft may pinch the boot between the driveshaft and damage the Constant Velocity (CV) joint flange which may cause the boot to tear. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Index-mark the front driveshaft at both ends to maintain driveshaft balance. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4290 3. NOTE: The new CV flange bolts and washers are not available and the originals are not damaged, they can be reused if the threads are coated with threadlock and sealer. NOTE: If new U-joint strap bolts are not available and the original bolts are not damaged, they can be reused if the threads are coated with threadlock and sealer. Remove and discard the 6 CV flange bolts and 3 CV joint washers. - To install, tighten the new bolts to 30 Nm (22 lb-ft). 4. NOTE: If new U-joint strap bolts are not available and the original bolts are not damaged, they can be reused if the threads are coated with threadlock and sealer. Remove the 4 U-joint strap bolts and remove the 2 U-joint straps. - Discard the bolts. - To install, tighten the new bolts to 19 Nm (168 lb-in). 5. Remove the front driveshaft. 6. NOTICE: Tighten the Constant Velocity (CV) joint bolts evenly in a cross pattern or damage will occur to the CV joint. NOTE: 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. NOTE: The CV joint is not serviceable. Install a new driveshaft if damaged. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4291 Driveshaft - Rear, One-Piece Driveshaft - Rear, One-Piece, 4.0L SOHC Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Make sure the index marks on the extension housing and driveshaft are aligned before separation. NOTE: After removing the driveshaft, place an index mark on the transmission output shaft that matches the transmission extension housing mark. Index-mark the driveshaft and the extension housing to maintain driveshaft balance. 3. Index-mark the driveshaft flange to the pinion flange to maintain driveshaft balance. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4292 4. NOTE: If new pinion flange bolts are not available and the originals are not damaged, they can be reused if the threads are coated with threadlock and sealer. Remove and discard the 4 driveshaft pinion flange bolts. - To install, tighten the new bolts to 112 Nm (83 lb-ft). 5. NOTE: The driveshaft flange yoke 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. Using a suitable tool, pry only in the area shown to separate the driveshaft flange yoke from the pinion flange and remove the driveshaft from the extension housing. 6. NOTE: The driveshaft flanges fit tightly on the pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the driveshaft flange bolts evenly in a cross pattern. NOTE: 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. Driveshaft - Rear, Two-Piece Driveshaft - Rear, Two-Piece, Four Wheel Drive (4WD) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4293 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 nuts from the driveshaft center bearing bracket. - To install, tighten to 55 Nm (41 lb-ft). 3. Index-mark the CV joint to the transfer case output flange. 4. Index-mark the rear U-joint flange to the differential pinion flange. 5. NOTE: If new CV flange bolts and washers are not available and the originals are not damaged, they can be reused if the threads are coated with threadlock and sealer. Remove and discard the 6 CV joint bolts and 3 CV joint washers. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4294 - To install, tighten the 6 new bolts to 30 Nm (22 lb-ft). 6. NOTE: If new flange bolts are not available and the originals are not damaged, they can be reused if the threads are coated with threadlock and sealer. Remove and discard the 4 driveshaft flange bolts. - To install, tighten the 4 new bolts to 112 Nm (83 lb-ft). 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 and remove the driveshaft. 9. To install, reverse the removal procedure. Driveshaft Slip Yoke Boot Driveshaft Slip Yoke Boot Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4295 Removal 1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear, One-Piece, 4.6L (3V) See: Driveshaft - Rear, One-Piece. 2. Index-mark the driveshaft on both sides of the driveshaft slip yoke boot. 3. Remove and discard the 2 driveshaft slip yoke boot clamps. 4. Separate the driveshaft. 5. Remove the driveshaft slip yoke boot. Installation 1. NOTE: Grease both ends of the driveshaft. Position the driveshaft slip yoke boot and the 2 driveshaft slip yoke boot clamps on one end of the driveshaft. 2. Align the index marks and connect the driveshaft. 3. Using the Keystone Clamp Installer, install the new driveshaft slip yoke boot. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 4296 4. Install the driveshaft. For additional information, refer to Driveshaft - Rear, One-Piece, 4.6L (3V) See: Driveshaft - Rear, One-Piece. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly and Assembly NOTE: The front driveshaft CV joint is not repairable. 1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear, One-Piece, 4.0L SOHC See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft - Rear, One-Piece, Driveshaft - Rear, One-Piece, 4.6L (3V) See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft Rear, One-Piece or Driveshaft - Front See: Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Driveshaft - Front. 2. Index-mark the components at the U-joints for reassembly. 3. Remove and discard the 4 snap rings. 4. Position the driveshaft in the C-Frame and Screw Installer/Remover. Using the C-Frame and Screw Installer/Remover, press out a bearing cup. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4301 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 C-Frame and Screw Installer/Remover. Using the C-Frame and Screw Installer/Remover, 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 U-joints for freedom of movement. If binding, strike the driveshaft flange with a brass or plastic hammer. Do not strike the U-joint. To assemble, reverse the disassembly procedure. - Use the yellow snap rings supplied in the kit to install the U-joint. If difficulty is encountered with the yellow snap rings, install the black snap rings, as required. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4302 Universal Joint: Service and Repair Driveshaft Universal Joint - Stake Type Driveshaft Universal Joint - Stake Type 1. The staked driveshaft U-joints are not serviced separately within the warranty period. Install a new driveshaft if worn or damaged. 2. U-joint service kits with instructions are available through a Ford authorized dealer for a high mileage repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Install the flexplate. Tighten the 8 new bolts in the sequence shown in 3 stages. Stage 1: Tighten to .............................................................................................................................................................. ........................13 Nm (115 lb-in). Stage 2: Tighten to......................................................................... ................................................................................................................50 Nm (37 lb-ft). Stage 3: Tighten an additional............................................................................................................................ .....................................................90 degrees. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Procedures Flex Plate: Procedures Flexplate Inspection 1. Inspect the flexplate for: 1. any cracks. 2. worn ring gear teeth. 3. chipped or cracked ring gear teeth. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Procedures > Page 4308 Flex Plate: Removal and Replacement Flexplate Removal 1. Remove the transmission. 2. Remove the 8 bolts and the flexplate. - Discard the bolts. Installation 1. NOTE: New flexplate bolts must be installed. They are a torque-to-yield design and cannot be reused. Install the flexplate. Tighten the 8 new bolts in 3 stages in the sequence shown. - Stage 1: Tighten to 13 Nm (115 lb-in). - Stage 2: Tighten to 50 Nm (37 lb-ft). - Stage 3: Tighten an additional 90 degrees. 2. Install the transmission. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and Operation Power Take-Off: Description and Operation Engine Control Components 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 (I/M) test, operate the vehicle with the PTO disengaged long enough to successfully complete the OBD Monitors. PTO Circuits Description The three 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 when the operator is requesting additional engine RPM for PTO operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4327 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4328 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4334 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4335 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4340 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 4343 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 4344 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 4345 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 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 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation Brake Switch - TCC: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Mode Switch: Description and Operation Engine Control Components 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. Typical Transmission Control Switch (TCS) (Column Shift) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) (Floor Shift) Typical Transmission Control Switch (TCS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS) External Controls Transmission Control Switch (TCS) The Transmission Control Switch (TCS) is a momentary contact switch located on the selector lever knob. Pushing the TCS will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on the Instrument Cluster (IC). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Service and Repair > Transmission Control Switch (TCS) > Page 4356 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. 2. Remove the Transmission Control Switch (TCS) from the knob. Installation 1. Install the TCS into the selector lever knob. 2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4360 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4361 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4362 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4363 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4364 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4365 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4366 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4367 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4368 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4373 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4374 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4375 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 4378 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 4379 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor 5R55S Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4382 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Turbine Shaft Speed (TSS) sensor connector. 8. Remove the TSS sensor. 1. Remove the TSS sensor screw. 2. Remove the TSS sensor from the transmission. - Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4383 Installation All vehicles 1. Inspect the TSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the TSS sensor into the transmission. 2. Tighten the TSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the TSS sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever bracket and selector lever bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4384 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4385 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor 5R55S Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4386 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Heated Oxygen Sensor (HO2S) connector from the transmission case. 8. Disconnect the Output Shaft Speed (OSS) sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4387 9. Remove the OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the OSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the OSS sensor into the transmission. 2. Tighten the OSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the OSS sensor connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4388 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4389 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4390 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor 5R55S Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4391 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor connector. 8. Remove the intermediate shaft speed sensor. 1. Remove the intermediate shaft speed sensor screw. 2. Remove the intermediate shaft speed sensor from the transmission. - Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4392 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the intermediate shaft speed sensor into the transmission. 2. Tighten the intermediate shaft speed sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the intermediate shaft speed sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4393 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4398 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4399 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 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. 6. Disconnect the electrical connector(s). 7. Disengage the locking tangs and remove the Mode Select Switch (MSS) from the instrument panel center finish panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4400 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. With the ignition ON, press the 4X4 HIGH button on the Mode Select Switch (MSS). 3. Remove the 3 heat shield bolts and the heat shield. - To install, tighten to 16 Nm (142 lb-in). 4. Disconnect the transfer case shift motor electrical connector. 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Page 4406 7. To install, reverse the removal procedure. - Apply a coat of multi-purpose grease to the transfer case shift motor bolts. - Apply a thin coat of silicone sealant to the shift motor mating surface. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4410 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 4413 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 4414 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 4415 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 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 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (1.4 Liters) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4420 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid.............................................................................................................................. ...................................Motorcraft Transfer Case Fluid Part Number......................................................................................................................................... ...........................................................................XL-12 Specification......................................................................................................................................... ..........................................................ESP-M2C166-H Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 4421 Fluid - Transfer Case: Service and Repair Transfer Case Draining and Filling 1. NOTICE: Transfer case failure can result if the correct fill procedures are not followed. NOTE: Position a suitable drain pan under the transfer case. Remove the drain plug and drain the fluid. 2. Clean and install the drain plug. - Tighten to 20 Nm (177 lb-in). 3. NOTICE: Incorrect fluid fill can result in transfer case failure. NOTE: Fill the transfer case with the vehicle on a level surface. Make sure the fluid is level with the filler opening for the correct fluid level. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4425 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4426 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 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. 6. Disconnect the electrical connector(s). 7. Disengage the locking tangs and remove the Mode Select Switch (MSS) from the instrument panel center finish panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4427 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 4432 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 4435 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > 4X4 Control Module > Page 4436 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 4437 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 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 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. With the transmission in NEUTRAL, position it on a hoist. 2. Index-mark the rear output flange and the driveshaft yoke. 3. NOTE: If new driveshaft yoke bolts are not available, coat the threads of the original bolts with threadlock and sealer. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 4441 Remove the 4 driveshaft yoke bolts. - To install, tighten to 112 Nm (83 lb-ft) evenly in a cross pattern. 4. NOTICE: 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 or damage to the components can occur. 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 Drive Pinion Flange Holding Fixture to hold the output flange, remove the nut. - To install, tighten to 355 Nm (262 lb-ft). 7. Remove the output shaft yoke washer. 8. Using the Output Shaft Flange Remover, remove the rear output shaft flange. 9. Remove and discard the rear output shaft flange oil seal. 10. Using the Bushing Remover with the Slide Hammer, remove the rear output shaft oil seal. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 4442 11. Using the Input Shaft Oil Seal Installer, install a new rear output shaft oil seal. 12. To install, reverse the removal procedure. - Always install a new rear output shaft flange oil seal. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4447 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4448 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 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. 6. Disconnect the electrical connector(s). 7. Disengage the locking tangs and remove the Mode Select Switch (MSS) from the instrument panel center finish panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4449 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. With the ignition ON, press the 4X4 HIGH button on the Mode Select Switch (MSS). 3. Remove the 3 heat shield bolts and the heat shield. - To install, tighten to 16 Nm (142 lb-in). 4. Disconnect the transfer case shift motor electrical connector. 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Page 4453 7. To install, reverse the removal procedure. - Apply a coat of multi-purpose grease to the transfer case shift motor bolts. - Apply a thin coat of silicone sealant to the shift motor mating surface. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal 1. Remove the front floor console. 2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector. 3. Remove the screw and the BSIA. Installation 1. Install the BSIA and the screw. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4460 2. Connect the BSIA electrical connector. 3. Install the front floor console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. With the ignition ON, press the 4X4 HIGH button on the Mode Select Switch (MSS). 3. Remove the 3 heat shield bolts and the heat shield. - To install, tighten to 16 Nm (142 lb-in). 4. Disconnect the transfer case shift motor electrical connector. 5. Using an electrical connector pin extractor tool, remove the coil wire pin from the electrical connector. 6. Remove the 4 transfer case shift motor mounting bolts and the transfer case shift motor. - To install, tighten to 10 Nm (89 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Page 4465 7. To install, reverse the removal procedure. - Apply a coat of multi-purpose grease to the transfer case shift motor bolts. - Apply a thin coat of silicone sealant to the shift motor mating surface. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Control Module: Customer Interest Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4481 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 4482 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 4488 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) 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: > 09-18-10 > Sep > 09 > Engine, A/T Controls Driveline Bump/Harsh 1-2 Shift > Page 4489 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4494 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > 4X4 Control Module Control Module: Diagrams 4X4 Control Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > 4X4 Control Module > Page 4497 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > 4X4 Control Module > Page 4498 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Diagrams > Page 4499 Control Module: Service and Repair 4X4 Control Module 1. Disconnect the battery ground cable. 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 4X4 control module. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Description and Operation Brake Switch - TCC: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Mode Switch: Description and Operation Engine Control Components 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. Typical Transmission Control Switch (TCS) (Column Shift) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) (Floor Shift) Typical Transmission Control Switch (TCS) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Service and Repair > Transmission Control Switch (TCS) Transmission Mode Switch: Service and Repair Transmission Control Switch (TCS) External Controls Transmission Control Switch (TCS) The Transmission Control Switch (TCS) is a momentary contact switch located on the selector lever knob. Pushing the TCS will either disengage or engage the overdrive function of the transmission. If OVERDRIVE is disengaged, the message Overdrive (O/D) OFF will illuminate on the Instrument Cluster (IC). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Service and Repair > Transmission Control Switch (TCS) > Page 4510 Transmission Mode Switch: Service and Repair Transmission Control (TC) Switch Transmission Control (TC) Switch Removal 1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. 2. Remove the Transmission Control Switch (TCS) from the knob. Installation 1. Install the TCS into the selector lever knob. 2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See: Automatic Transmission/Transaxle/Shifter A/T/Service and Repair/Selector Lever Knob. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Transmission Position Switch/Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4514 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4515 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4516 Transmission Position Switch/Sensor: Adjustments 5R55S Transmission Range (TR) Sensor Adjustment Adjust 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 3. Move the rubber boot back to gain access to the Transmission Range (TR) sensor connector. 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable end from the manual control lever. 6. Remove the manual control lever nut and the manual control lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4517 7. Loosen but do not remove the TR sensor screws. 8. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. - Tighten to 8 Nm (71 lb-in). 9. Install the manual control lever and manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 10. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 11. Reconnect the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4518 12. Reinstall the rubber boot over the TR connector. 13. NOTE: If the selector lever cable shield is loose on the selector lever cable, replace the selector lever cable shield. Install the selector lever cable shield. 14. Verify that the selector lever cable is adjusted correctly. 15. Verify that the vehicle will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4519 Transmission Position Switch/Sensor: Service and Repair 5R55S Digital Transmission Range (TR) Sensor Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 3. Move the TR sensor connector boot back to gain access to the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4520 4. Disconnect the TR sensor connector. 5. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable from the manual control lever. 6. Remove the manual control lever nut. 7. Remove the TR sensor. Installation 1. NOTICE: The Transmission Range (TR) sensor must fit flush against the boss on the case to prevent damage to the sensor. Install the TR sensor and loosely install the TR sensor screw and washer (2 required). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4521 2. NOTICE: Tightening one screw before tightening the other may cause the sensor to bind or become damaged. NOTE: The manual control lever must be in the NEUTRAL position. Using the TR Sensor Alignment Gauge, align the TR sensor and tighten the screws in an alternating sequence. Tighten to 8 Nm (71 lb-in). 3. Install the manual control lever and the manual control lever nut. - Tighten to 48 Nm (35 lb-ft). 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable end onto the manual control lever ball stud. 5. Connect the TR sensor connector. 6. Move the TR sensor connector boot back over the TR sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4522 7. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 8. Verify that the selector lever cable is adjusted correctly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4527 Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4528 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 4529 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 4532 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Output Shaft Speed (OSS) Sensor > Page 4533 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor 5R55S Turbine Shaft Speed (TSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4536 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Turbine Shaft Speed (TSS) sensor connector. 8. Remove the TSS sensor. 1. Remove the TSS sensor screw. 2. Remove the TSS sensor from the transmission. - Inspect the TSS sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4537 Installation All vehicles 1. Inspect the TSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the TSS sensor into the transmission. 2. Tighten the TSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the TSS sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever bracket and selector lever bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4538 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4539 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor 5R55S Output Shaft Speed (OSS) Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4540 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the Heated Oxygen Sensor (HO2S) connector from the transmission case. 8. Disconnect the Output Shaft Speed (OSS) sensor connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4541 9. Remove the OSS sensor. 1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission. - Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring. Installation All vehicles 1. Inspect the OSS O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the OSS sensor into the transmission. 2. Tighten the OSS sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the OSS sensor connector. 3. Connect the HO2S connector to the transmission case. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4542 4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 5. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. 4WD vehicles 6. Install the front driveshaft in the vehicle. 7. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 8. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4543 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4544 Transmission Speed Sensor: Service and Repair Intermediate Shaft Speed Sensor 5R55S Intermediate Shaft Speed Sensor Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Four-Wheel Drive (4WD) vehicles 2. Disconnect the front driveshaft from the transfer case. 3. Disconnect the front driveshaft from the front differential. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4545 4. Remove the front driveshaft from the vehicle. All vehicles 5. Remove the selector lever cable shield by prying on the side of the selector lever cable shield closest to the Transmission Range (TR) sensor connector boot, then sliding the selector lever cable shield away from the TR sensor connector boot. 6. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. Remove the selector lever cable and selector lever cable bracket. 7. Disconnect the intermediate shaft speed sensor connector. 8. Remove the intermediate shaft speed sensor. 1. Remove the intermediate shaft speed sensor screw. 2. Remove the intermediate shaft speed sensor from the transmission. - Inspect the intermediate shaft speed sensor O-ring for damage. If damaged, install a new O-ring. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4546 Installation All vehicles 1. Inspect the O-ring seal for damage. Install a new O-ring seal if damaged. Lubricate the O-ring seal with petroleum jelly to prevent damage to the O-ring seal. 1. Install the intermediate shaft speed sensor into the transmission. 2. Tighten the intermediate shaft speed sensor screw. - Tighten to 14 Nm (124 lb-in). 2. Connect the intermediate shaft speed sensor connector. 3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable between the manual control lever and the selector lever cable bracket. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is correctly installed onto the manual control lever ball stud. Pull back on the selector lever cable to make sure that the selector cable end is correctly installed onto the manual control lever ball stud. Install the selector lever cable, selector lever cable bracket and selector lever cable bracket screws. - Tighten to 40 Nm (30 lb-ft). 4. NOTE: If the selector lever cable shield is loose on the selector lever cable, install a new selector lever cable shield. Install the selector lever cable shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 4547 4WD vehicles 5. Install the front driveshaft in the vehicle. 6. Connect the front driveshaft to the transfer case. Install the CV joint washers and CV joint bolts. - Tighten to 30 Nm (22 lb-ft). 7. Connect the front driveshaft to the front differential. Install the U-joint straps and U-joint strap bolts. - Tighten to 19 Nm (168 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4552 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4553 Four Wheel Drive Selector Switch: Service and Repair Mode Select Switch (MSS) Removal and Installation 1. Disconnect the battery ground cable. 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. 6. Disconnect the electrical connector(s). 7. Disengage the locking tangs and remove the Mode Select Switch (MSS) from the instrument panel center finish panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4554 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block > Component Information > Locations > Page 4560 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Service and Repair Acceleration/Deceleration Sensor: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. - To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 4564 - To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4568 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 4569 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4573 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4574 Electronic Brake Control Module: Diagrams Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4575 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 4576 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation NOTICE: Electronic modules are sensitive to electrical charges. The Anti-lock Brake System (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 Programmable Module Installation in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control Unit (HCU) See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair. 2. Remove the 4 screws and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 3. NOTICE: Make sure that the Anti-lock Brake System (ABS) module is properly seated to the Hydraulic Control Unit (HCU) and that the torque of the ABS module screws is correct, or damage to the components can occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 4580 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery tray. 3. Disconnect the ABS module electrical connector. 4. NOTE: The brake tubes must be installed in the same location as removed. Disconnect the master cylinder primary and secondary brake tube-to-Hydraulic Control Unit (HCU) fittings and position both brake tubes aside. - To install, tighten to 25 Nm (18 lb-ft). 5. NOTE: The brake tubes must be installed in the same location as removed. Disconnect the 4 brake tube-to-HCU extension tube fittings. - To install, tighten to 18 Nm (159 lb-in). 6. Remove the 3 HCU bracket-to-frame nuts and the HCU assembly. - To install, tighten the nuts to 23 Nm (17 lb-ft). 7. NOTE: The brake tubes must be installed in the same location as removed. Disconnect the 4 HCU extension tube-to-HCU fittings. - To install, tighten to 18 Nm (159 lb-in). 8. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer assembly. - To install, tighten the nuts to 9 Nm (80 lb-in). 9. Remove the HCU bracket-to-HCU bolt and the HCU bracket. - To install, tighten the bolts to 9 Nm (80 lb-in). 10. To install, reverse the removal procedure. - Bleed the brake system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 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 screws and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 4587 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 4588 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 lb-in). 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 center finish panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4593 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4594 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4595 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4596 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4597 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4598 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4599 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4602 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4603 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4604 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 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. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt and the wheel speed sensor. - To install, tighten the bolt to 17 Nm (150 lb-in). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4607 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 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 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4608 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear Wheel Speed Sensor Ring - Rear Removal 1. Remove the rear halfshaft. 2. Using a suitable driver, remove the ABS wheel speed sensor ring. Installation 1. Install the new ABS wheel speed sensor and the Wheel Speed Sensor Ring Installers on the halfshaft as shown. 2. Using the Wheel Speed Sensor Ring Installers, install the ABS wheel speed sensor ring as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4609 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Master Cylinder Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder is installed, or the system is emptied or partially emptied, it should be primed to prevent air from entering the system. 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake master cylinder reservoir with clean, specified brake fluid. 4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 5. Remove the short brake tubes and install the brake outlet tubes. 6. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 2. Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4614 tighten 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. 5. Tighten the brake tube fittings to specifications. For additional information, refer to Specifications. 7. Bleed the brake system, refer to Brake System Bleeding See: Brake System Bleeding. Brake Caliper Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4615 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4616 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Pressure WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the equipment manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4617 4. Open the valve on the bleeder tank. - Set pressure to 207-345 kPa (30-50 psi). 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. Tighten to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw ending with the LH front bleeder screw. 7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter from the brake fluid reservoir. Manual WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Remove the bleeder screw cap and place a box-end wrench on the RH rear bleeder screw. Attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4618 3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order. Hydraulic Control Unit (HCU) NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system. 2. Connect the scan tool and follow the ABS Service Bleed instructions. 3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. Removal 1. NOTICE: Do not service the brake pedal without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch. Remove the stoplamp switch. 2. If equipped, remove the speed control deactivator switch. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 4623 3. NOTE: If equipped with adjustable pedals, when removing the adjustable pedal assembly, make sure the pedals are adjusted to the full rearward position. 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. 4. Disconnect the brake booster rod from the brake pedal and position aside. 5. If equipped with power adjustable pedals, disconnect the adjustable pedal motor electrical connector. 6. If equipped with adjustable pedals, disconnect the accelerator pedal motor electrical connector. 7. Remove and discard the 2 brake pedal bracket bolts. 8. Remove and discard the 4 brake booster nuts. 9. Position the brake master cylinder and brake booster assembly forward to allow the brake pedal assembly to clear the studs. 10. Remove the 3 accelerator pedal bracket nuts. 11. Remove the 2 steering column opening cover screws and the steering column opening cover panel. 12. NOTICE: 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. NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position. 13. Remove the steering column shaft bolt and disconnect the steering column shaft from the steering column. 14. 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 lb-ft). 4. Install the 2 new brake pedal bracket bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 4624 - Tighten to 22 Nm (16 lb-ft). 5. Install the 3 accelerator pedal bracket nuts. - Tighten to 7 Nm (62 lb-in). 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 column to the steering column shaft and install the bolt. - Tighten to 30 Nm (22 lb-ft). 11. Position the steering column opening cover and install the 2 screws. 12. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches. Install the stoplamp switch. 13. If equipped, install the speed control deactivator switch. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake Pedal and Bracket > Page 4625 Brake Pedal Assy: 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 lb-in). 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4635 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 (V6-4.0L (2009)) 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 4636 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4642 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 (V6-4.0L (2009)) 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 4643 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 (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 09-21-7 > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 4649 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 09-21-7 > Nov > 09 > Instruments - Trip Odometers/Fuel Economy Resets > Page 4655 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers Brake Caliper: Testing and Inspection Brake Calipers Brake System Inspection Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 4658 Brake Caliper: Testing and Inspection Brake Caliper Guide Pins Brake System Inspection Brake Caliper Guide Pins 1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. - Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. - Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. - Inspect the brake pads. For additional information, refer to Brake Pads inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Pads Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4661 Brake Caliper: Removal and Replacement Brake Caliper Brake Caliper Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the wheel and tire. 2. Remove the brake flexible hose flow bolt and position the brake hose aside. - Discard the 2 copper washers. - Cap the fluid ports. 3. NOTICE: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4662 Installation 1. Position the brake caliper and install the 2 guide pin bolts. - Tighten to 72 Nm (53 lb-ft). 2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. - Tighten to 35 Nm (26 lb-ft). 3. Bleed the brake caliper. 4. Install the wheel and tire. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. For additional information, refer to Brake Pads See: Brake Pad/Service and Repair/Front Disc Brake. 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 lb-ft). 3. To install, reverse the removal procedure. Rear Disc Brake Brake Caliper Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4663 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 1. Remove the wheel and tire. 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 lb-ft). 3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. - Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4664 4. Bleed the brake caliper. 5. Install the wheel and tire. - Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4673 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 (V6-4.0L (2009)) 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 4674 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4680 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 (V6-4.0L (2009)) 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 4681 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 (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 4682 Brake Pad: Specifications Brake pad minimum thickness.............................................................................................................. ........................................................3.0 mm (0.118 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 4683 Brake Pad: Testing and Inspection Brake System Inspection Brake Pads NOTE: It is not required to install new brake pads when the brake discs are machined. 1. Inspect the brake pad friction material for contamination. - If the friction material shows evidence of contamination, install new brake pads. 2. Inspect and measure the thickness of the brake pad friction material. For additional information, refer to Specifications. - Minor surface cracks do not require pad replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. - If the thickness of the friction material is less than the specified thickness, install new brake pads. - If the friction material shows taper wear that is not within specifications, install new brake pads and verify the caliper guide pins are functioning correctly. For additional information, refer to Brake Caliper Guide Pins inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Caliper Guide Pins Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake Brake Pad: Service and Repair Front Disc Brake Brake Pads Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface 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 one-half full. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4686 2. Remove the wheel and tire. 3. NOTICE: Do not pry in the brake caliper sight hole to retract the pistons as this can damage the pistons and boots. NOTICE: 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. Remove the brake pads and clips. - Discard the clips. Installation 1. 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. NOTICE: Protect the piston and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur. Using a C-clamp and a worn brake pad, compress the disc brake caliper pistons into the caliper. 3. Position the brake caliper and install the 2 guide pin bolts. - Tighten to 72 Nm (53 lb-ft). 4. Fill the brake master cylinder reservoir with clean specified brake fluid. 5. Install the wheel and tire. - Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4687 Brake Pad: Service and Repair Rear Disc Brake Brake Pads Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Check the brake fluid level in the brake master cylinder reservoir. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Disc Brake > Page 4688 - If required, remove the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. 3. NOTICE: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots. NOTICE: 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. Remove the 2 brake pads. - Discard the brake pad clips. Installation 1. Apply a thin bead of the specified sealant to the center of the inside of the brake pad clips. 2. Install the brake pad clips and brake pads. 3. NOTICE: Protect the piston and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur. If installing new brake pads, using a suitable tool and a worn brake pad, compress the disc brake caliper pistons into the caliper. 4. Position the brake caliper and install the 2 brake caliper guide pin bolts. - Tighten to 32 Nm (24 lb-ft). 5. Fill the brake master cylinder reservoir with clean, specified brake fluid. 6. Install the wheel and tire. - Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front Brake Rotor/Disc Brake Rotor/Disc: Specifications Front Brake Rotor/Disc Front Brake disc minimum thickness.................................................................................................... ......................................................28.5 mm (1.122 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Front Brake Rotor/Disc > Page 4693 Brake Rotor/Disc: Specifications Rear Brake Rotor/Disc Rear Brake disc minimum thickness.................................................................................................... .......................................................11.0 mm (0.433 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 4694 Brake Rotor/Disc: Testing and Inspection Brake System Inspection Brake Discs NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This causes brake disc on-vehicle lateral runout and brake roughness. 1. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around the circumference of the brake disc. Record the measurements, refer to Specifications. If the brake disc is cracked or otherwise damaged, install a new brake disc. - If any measurement is below the minimum thickness specification, install a new brake disc. - If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification. For additional information, refer to Specifications and Brake Disc Machining See: Service and Repair/Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing the lathe. NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the lathe is not self adjusting, the lathe oscillation must be adjusted using a dial indicator. The total indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050 mm (0.002 in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the final brake disc runout will be within specification and a runout measurement is not necessary after machining. 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 specification. 1. Remove the wheel and tire. 2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as required. - Support the brake caliper using mechanic's wire. 3. Install the hub adapter using: - four wheel nuts on a 4-stud wheel hub. - five wheel nuts on a 5-stud wheel hub. - six wheel nuts on a 6-stud wheel hub. - four wheel nuts on a 7- or 8-stud wheel hub. - five wheel nuts on a 10-stud wheel hub. 4. Install the cutting lathe. 5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050 mm (0.002 in). 6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer. 7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). 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. 8. Remove the lathe and the silencer. 9. Remove the wheel nuts and hub adapter. 10. Remove the metal shavings. 11. NOTE: It is not required to install new brake pads if friction material is within specifications. For additional information, refer to Specifications. Position the brake caliper or brake caliper and anchor plate assembly. - Install the bolts. - For fastener torque specifications, refer to Disc Brake System. See: Specifications 12. Install the wheel and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4697 Brake Rotor/Disc: Removal and Replacement Brake Disc Brake Disc Removal 1. NOTICE: 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. 2. NOTE: If the brake disc cannot be removed easily, apply specified 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 specified parts cleaner to clean the front brake disc and hub surfaces. 2. Apply a thin coat of specified 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 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4698 Brake Disc Shield Brake Disc Shield Removal and Installation 1. Remove the brake disc. For additional information, refer to Brake Disc See: Front Disc Brake/Brake Disc. 2. Remove and discard the 4 brake disc shield bolts. - To install, tighten new bolts to 8 Nm (71 lb-in). 3. Remove the brake disc shield. 4. To install, reverse the removal procedure. Brake Disc Brake Disc Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4699 Removal 1. Remove the wheel and tire. 2. NOTICE: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots. NOTICE: 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 specified penetrating and 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 specified 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 lb-ft). 4. Install the wheel and tire. - Apply brakes several times to verify correct brake operation. Brake Disc Shield Brake Disc Shield Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 4700 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 lb-in). 2. Install the parking brake shoes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding Brake Bleeding: Service and Repair Component Bleeding Master Cylinder Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder is installed, or the system is emptied or partially emptied, it should be primed to prevent air from entering the system. 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake master cylinder reservoir with clean, specified brake fluid. 4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 5. Remove the short brake tubes and install the brake outlet tubes. 6. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 2. Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4706 tighten 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. 5. Tighten the brake tube fittings to specifications. For additional information, refer to Specifications. 7. Bleed the brake system, refer to Brake System Bleeding See: Brake System Bleeding. Brake Caliper Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4707 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4708 Brake Bleeding: Service and Repair Brake System Bleeding Brake System Bleeding Pressure WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the equipment manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the bleeding operation. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4709 4. Open the valve on the bleeder tank. - Set pressure to 207-345 kPa (30-50 psi). 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. Tighten to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. 6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder screw ending with the LH front bleeder screw. 7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter from the brake fluid reservoir. Manual WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with clean, specified brake fluid. 2. Remove the bleeder screw cap and place a box-end wrench on the RH rear bleeder screw. Attach a rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Component Bleeding > Page 4710 3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. 6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order. Hydraulic Control Unit (HCU) NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new. NOTE: Pressure bleeding the brake system is preferred to manual bleeding. 1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system. 2. Connect the scan tool and follow the ABS Service Bleed instructions. 3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4719 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 (V6-4.0L (2009)) 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 4720 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 4726 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 (V6-4.0L (2009)) 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 4727 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 (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers Brake Caliper: Testing and Inspection Brake Calipers Brake System Inspection Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > Brake Calipers > Page 4730 Brake Caliper: Testing and Inspection Brake Caliper Guide Pins Brake System Inspection Brake Caliper Guide Pins 1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. - Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. - Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. - Inspect the brake pads. For additional information, refer to Brake Pads inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Pads Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Component Bleeding Brake Caliper WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was disconnected or installed new. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid. 2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information, refer to Specifications. - Install the bleeder screw cap. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4733 Brake Caliper: Removal and Replacement Brake Caliper Brake Caliper Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the wheel and tire. 2. Remove the brake flexible hose flow bolt and position the brake hose aside. - Discard the 2 copper washers. - Cap the fluid ports. 3. NOTICE: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4734 Installation 1. Position the brake caliper and install the 2 guide pin bolts. - Tighten to 72 Nm (53 lb-ft). 2. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. - Tighten to 35 Nm (26 lb-ft). 3. Bleed the brake caliper. 4. Install the wheel and tire. Brake Caliper Anchor Plate Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. For additional information, refer to Brake Pads See: Disc Brake System/Brake Pad/Service and Repair/Front Disc Brake. 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 lb-ft). 3. To install, reverse the removal procedure. Rear Disc Brake Brake Caliper Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4735 Removal WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. 1. Remove the wheel and tire. 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 lb-ft). 3. Using 2 new copper washers, position the brake hose and install the brake hose flow bolt. - Tighten to 35 Nm (26 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 4736 4. Bleed the brake caliper. 5. Install the wheel and tire. - Apply brakes several times to verify correct brake operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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-C Ford Specification ................................................................................................................................................... WSS-M6C62-A or WSS-M6C65-A1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4743 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4744 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection Brake Hose/Line: Testing and Inspection Brake System Inspection Brake Flexible Hoses and Tubes NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in brake tube failure. NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. 1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage. - If a section of the brake tube is damaged, the entire section must be installed with a new tube of the same type, size, shape and length. - When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to specifications. After installation, bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding. 2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other signs of damage. - Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Disc Brake Brake Hose/Line: Service and Repair Front Disc Brake Brake Flexible Hose Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the brake flexible hose flow bolt and discard the 2 copper washers. - To install, tighten to 35 Nm (26 lb-ft). - Use 2 new copper washers. 2. Disconnect the brake tube fitting from the brake flexible hose. - To install, tighten to 18 Nm (159 lb-in). 3. Remove the brake flexible hose retaining clip and the brake flexible hose. 4. To install, reverse the removal procedure. - Bleed the brake caliper. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Front Disc Brake > Page 4750 Brake Hose/Line: Service and Repair Rear Disc Brake Brake Flexible Hose Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Remove the wheel and tire. 2. Remove the brake caliper flow bolt and discard the 2 copper washers. - To install, tighten to 35 Nm (26 lb-ft). 3. Disconnect the brake tube fitting from the brake flexible hose. - To install, tighten to 18 Nm (159 lb-in). 4. Remove the brake flexible hose bracket bolt and the brake hose. - To install, tighten to 20 Nm (177 lb-in). 5. To install, reverse the removal procedure. - Bleed the brake caliper. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Page 4754 WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery tray. 3. Disconnect the ABS module electrical connector. 4. NOTE: The brake tubes must be installed in the same location as removed. Disconnect the master cylinder primary and secondary brake tube-to-Hydraulic Control Unit (HCU) fittings and position both brake tubes aside. - To install, tighten to 25 Nm (18 lb-ft). 5. NOTE: The brake tubes must be installed in the same location as removed. Disconnect the 4 brake tube-to-HCU extension tube fittings. - To install, tighten to 18 Nm (159 lb-in). 6. Remove the 3 HCU bracket-to-frame nuts and the HCU assembly. - To install, tighten the nuts to 23 Nm (17 lb-ft). 7. NOTE: The brake tubes must be installed in the same location as removed. Disconnect the 4 HCU extension tube-to-HCU fittings. - To install, tighten to 18 Nm (159 lb-in). 8. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer assembly. - To install, tighten the nuts to 9 Nm (80 lb-in). 9. Remove the HCU bracket-to-HCU bolt and the HCU bracket. - To install, tighten the bolts to 9 Nm (80 lb-in). 10. To install, reverse the removal procedure. - Bleed the brake system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Component Tests Brake Master Cylinder - Bypass Condition 1. Inspect the master cylinder. For additional information, refer to Brake System Inspection See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection. 2. Disconnect the brake tubes from the master cylinder. 3. Plug the outlet ports of the master cylinder. 4. NOTE: Make sure that the outlet port plugs do not show signs of leakage. Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with heavy force. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new brake master cylinder must be installed. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4759 Brake Master Cylinder: Testing and Inspection Brake Master Cylinder - Compensator Port Component Tests Brake Master Cylinder - Compensator Port 1. Inspect the master cylinder. For additional information, refer to Brake System Inspection See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection. 2. With the vehicle in NEUTRAL, position it on a hoist. Refer to Maintenance/Service and Repair. 3. Apply and release the brakes. 4. With the brakes released, attempt to rotate each wheel and check for any brake drag. - If an excessive amount of brake drag exists at multiple wheels, continue to Step 4. - If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized brake caliper, brake wheel cylinder or parking brake component. Repair or install new components as necessary. 5. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not partially applied. 6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake booster. 7. With the brakes released, attempt to rotate each wheel and check for any brake drag. - If the brake drag is no longer present, install a new brake booster. - If the brake drag is still present, install a new master cylinder. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4760 Brake Master Cylinder: Testing and Inspection Brake System Inspection Brake Pads Brake System Inspection Brake Pads NOTE: It is not required to install new brake pads when the brake discs are machined. 1. Inspect the brake pad friction material for contamination. - If the friction material shows evidence of contamination, install new brake pads. 2. Inspect and measure the thickness of the brake pad friction material. For additional information, refer to Specifications. - Minor surface cracks do not require pad replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. - If the thickness of the friction material is less than the specified thickness, install new brake pads. - If the friction material shows taper wear that is not within specifications, install new brake pads and verify the caliper guide pins are functioning correctly. For additional information, refer to Brake Caliper Guide Pins inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Caliper Guide Pins Brake Discs Brake System Inspection Brake Discs NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This causes brake disc on-vehicle lateral runout and brake roughness. 1. Inspect the brake discs and measure the brake disc thickness in a minimum of 4 places around the circumference of the brake disc. Record the measurements, refer to Specifications. If the brake disc is cracked or otherwise damaged, install a new brake disc. - If any measurement is below the minimum thickness specification, install a new brake disc. - If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification. For additional information, refer to Specifications and Brake Disc Machining See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Procedures. Brake Calipers Brake System Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4761 Brake Calipers 1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding. - If the brake caliper is leaking or otherwise damaged, install a new brake caliper. Brake Caliper Guide Pins Brake System Inspection Brake Caliper Guide Pins 1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. - Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. - Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. - Inspect the brake pads. For additional information, refer to Brake Pads inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection/Brake Pads Brake Flexible Hoses and Tubes Brake System Inspection Brake Flexible Hoses and Tubes NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in brake tube failure. NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube. 1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage. - If a section of the brake tube is damaged, the entire section must be installed with a new tube of the same type, size, shape and length. - When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to specifications. After installation, bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4762 2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other signs of damage. - Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage. Brake Master Cylinder Brake System Inspection Brake Master Cylinder NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will fall during brake application and rise during release. The returning brake fluid creates a slight turbulance in the master cylinder reservoir. This is a normal condition and indicates that the compensator ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. The net fluid level (such as after brake application and release) will remain unchanged. Fluid level will decrease with pad wear. NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. 1. Inspect the brake master cylinder for fluid leaks. - Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present. For additional information, refer to Brake Master Cylinder. - To check for correct brake master cylinder operation, refer to Component Tests See: Testing and Inspection/Component Tests and General Diagnostics. Brake Booster Brake System Inspection Brake Booster 1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and kinks. - Install a new brake booster if signs of excessive corrosion or damage is found. For additional information, refer to Power Brake Assist. - Repair or replace vacuum hoses as necessary. - To check for correct brake booster operation, refer to Component Tests See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Brake Master Cylinder - Bypass Condition > Page 4763 Brake Master Cylinder: Testing and Inspection Brake Booster Component Tests Brake Booster 1. Inspect the brake booster. For additional information, refer to Brake System Inspection See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection. 2. Disconnect the check valve from the brake booster and connect a suitable vacuum/pressure tester to the booster side of the check valve. 3. Apply the parking brake, start the engine and place the transmission in NEUTRAL. - Allow the engine to reach normal operating temperature. 4. NOTE: Subtract approximately 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8 m (1,000 ft) of elevation above sea level. Verify that vacuum is available at the check valve with engine running at normal idle speed. - The vacuum gauge should read between 51-74 kPa (15-22 in-Hg). - If specified vacuum is available, stop the engine, connect the check valve and continue with Step 5. - If specified vacuum is not available, continue with Step 4. 5. Disconnect the check valve from the vacuum hose and verify that the specified vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL. If specified vacuum is available, stop the engine, install a new check valve and continue with Step 5. - If specified vacuum is not available, stop the engine, connect the vacuum hose to the check valve and refer to Engine to diagnose the no/low vacuum condition. See: Engine, Cooling and Exhaust/Engine/Testing and Inspection 6. Apply the brake pedal several times to exhaust all vacuum from the system. 7. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake pedal moves downward after the engine starts. - If the brake pedal moves, the brake booster is operating correctly. - If the brake pedal does not move, install a new brake booster. 8. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand for 10 minutes, then apply the brake pedal. 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 condition still exists, install a new brake booster. - If the brake pedal feels the same as noted with the engine operating, the check valve is functioning properly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures Component Bleeding Master Cylinder WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance. Failure to follow this instruction may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. NOTE: When a new brake master cylinder is installed, or the system is emptied or partially emptied, it should be primed to prevent air from entering the system. 1. Disconnect the brake tubes from the master cylinder. 2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir. 3. Fill the brake master cylinder reservoir with clean, specified brake fluid. 4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air bubbles. 5. Remove the short brake tubes and install the brake outlet tubes. 6. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake pedal. 2. Loosen the rearmost brake tube fitting until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3. Repeat this operation until clear, bubble-free fluid comes out. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4766 4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. 5. Tighten the brake tube fittings to specifications. For additional information, refer to Specifications. 7. Bleed the brake system, refer to Brake System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4767 Brake Master Cylinder: Removal and Replacement Brake Master Cylinder Removal and Installation WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. With the engine off, press the brake pedal several times to deplete the brake booster vacuum. 2. Disconnect the brake fluid level warning switch electrical connector. 3. Disconnect the 2 brake tube fittings from the brake master cylinder. - To install, tighten to 18 Nm (159 lb-in). 4. Remove the 2 nuts, the brake master cylinder and the square cut seal. - To install, tighten to 25 Nm (18 lb-ft). 5. NOTE: Make sure that the square cut seal is properly installed or incorrect brake pedal feel can occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 4768 - Bleed the brake system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures Parking Brake Cable: Procedures 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 in) x 150 mm (5.9 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4774 Parking Brake Cable: Removal and Replacement Parking Brake Cable - Rear, LH Parking Brake Cable - Rear, LH Removal and Installation 1. Release the parking brake cable tension. For additional information, refer to Parking Brake Cable Tension Release See: Procedures. 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the wire form bolt. - To install, tighten to 23 Nm (17 lb-ft). 4. Remove the bracket bolt. - To install, tighten to 23 Nm (17 lb-ft). 5. Disconnect the intermediate cable from the LH rear cable at the cable equalizer. 6. Disconnect the front of the LH rear cable conduit at the frame bracket. 7. Disconnect the LH parking brake cable from the parking brake lever and remove the cable. 8. To install, reverse the removal procedure. - Test the parking brake system for correct operation. Parking Brake Cable - Rear, RH Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4775 Parking Brake Cable - Rear, RH Removal and Installation 1. Release the parking brake cable tension. For additional information, refer to Parking Brake Cable Tension Release See: Procedures. 2. With the vehicle in NEUTRAL position it on a hoist. 3. Remove the 2 wire form bolts. - To install, tighten to 15 Nm (133 lb-in). 4. Remove the 2 parking brake cable bracket-to-crossmember bolts. - To install, tighten to 15 Nm (133 lb-in). 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. Parking Brake Cable - Front Parking Brake Cable - Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4776 Removal and Installation 1. Remove the parking brake control. For additional information, refer to Parking Brake Control See: Parking Brake Control/Service and Repair. 2. 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. 3. To install, reverse the removal procedure. - Test the parking brake system for correct operation. Parking Brake Cable - Intermediate Parking Brake Cable - Intermediate NOTE: The equalizer is integral to the intermediate cable. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 4777 Removal and Installation 1. Release the tension on the parking brake cable. For additional information, refer to Parking Brake Cable Tension Release See: Procedures. 2. With the vehicle in NEUTRAL, position it on a hoist. 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 (V6-4.0L (2009)) 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 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. For additional information, refer to Parking Brake Cable Tension Release See: Parking Brake Cable/Service and Repair/Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Page 4781 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 lb-in). 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 (177 lb-in). 10. Position the carpet aside and position the cable conduit grommet up through the floor. 11. Remove the parking brake control and cable assembly. 12. To install, reverse the removal procedure. - Test the parking brake system for correct operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications Parking Brake Shoe: Specifications Minimum Thickness.............................................................................................................................. .....................................................0.54 mm (0.021 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4785 Parking Brake Shoe: Adjustments Parking Brake Shoe Adjustment 1. NOTE: Make sure the parking brake is fully released. Using the release handle, release the parking brake control. 2. Remove the rear brake disc. 3. Using the Brake Adjusting Gauge, measure the inside diameter of the drum portion of the rear brake disc and set the locking screw. - Record the measurement. 4. Place the Brake Adjusting Gauge over the widest diameter of the parking brake shoes. 5. Adjust the parking brake shoe clearance to 0.54 mm (0.021 in) less than the inside diameter of the drum portion of the rear brake disc. - Rotate the parking brake shoe adjuster to achieve the correct parking brake shoe-to-brake disc clearance. 6. Install the rear brake disc. 7. Test the parking brake for normal operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4786 Parking Brake Shoe: Service and Repair Parking Brake Shoes 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. For additional information, refer to Parking Brake Cable Tension Release See: Parking Brake Cable/Service and Repair/Procedures. 2. Remove the rear brake disc. 3. Remove the parking brake shoe adjusting screw. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications > Page 4787 5. Adjust the parking brake shoe. For additional information, refer to Parking Brake Shoe Adjustment See: Adjustments. 6. Reload the tension on the parking brake cable. For additional information, refer to Parking Brake Cable Tension Release See: Parking Brake Cable/Service and Repair/Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4791 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 4792 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4797 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4798 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4802 Vacuum Brake Booster: Description and Operation Brake Booster The power brake actuation system consists of the following components: - Brake booster - Brake booster check valve - Brake booster vacuum supply hose The brake booster uses engine vacuum from the intake manifold to create a partial vacuum inside the vacuum booster on both sides of the diaphragm. When the brake pedal is pressed, the booster rod opens a valve, allowing air to enter the booster on one side of the diaphragm while sealing off the opposite side. This increases pressure on that side of the diaphragm so that it helps push the rod, which in turn pushes the piston in the master cylinder. As the brake pedal is released, the valve seals off the outside air supply while opening the vacuum valve. This restores vacuum to both sides of the diaphragm, allowing everything to return to its original position. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Brake Booster Vacuum Brake Booster: Testing and Inspection Brake Booster Component Tests Brake Booster 1. Inspect the brake booster. For additional information, refer to Brake System Inspection See: Testing and Inspection/Component Tests and General Diagnostics/Brake System Inspection. 2. Disconnect the check valve from the brake booster and connect a suitable vacuum/pressure tester to the booster side of the check valve. 3. Apply the parking brake, start the engine and place the transmission in NEUTRAL. - Allow the engine to reach normal operating temperature. 4. NOTE: Subtract approximately 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8 m (1,000 ft) of elevation above sea level. Verify that vacuum is available at the check valve with engine running at normal idle speed. - The vacuum gauge should read between 51-74 kPa (15-22 in-Hg). - If specified vacuum is available, stop the engine, connect the check valve and continue with Step 5. - If specified vacuum is not available, continue with Step 4. 5. Disconnect the check valve from the vacuum hose and verify that the specified vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL. If specified vacuum is available, stop the engine, install a new check valve and continue with Step 5. - If specified vacuum is not available, stop the engine, connect the vacuum hose to the check valve and refer to Engine to diagnose the no/low vacuum condition. See: Engine, Cooling and Exhaust/Engine/Testing and Inspection 6. Apply the brake pedal several times to exhaust all vacuum from the system. 7. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake pedal moves downward after the engine starts. - If the brake pedal moves, the brake booster is operating correctly. - If the brake pedal does not move, install a new brake booster. 8. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand for 10 minutes, then apply the brake pedal. 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 condition still exists, install a new brake booster. - If the brake pedal feels the same as noted with the engine operating, the check valve is functioning properly. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Brake Booster > Page 4805 Vacuum Brake Booster: Testing and Inspection Brake System Inspection - Brake Booster Brake System Inspection Brake Booster 1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and kinks. - Install a new brake booster if signs of excessive corrosion or damage is found. For additional information, refer to Power Brake Assist. - Repair or replace vacuum hoses as necessary. - To check for correct brake booster operation, refer to Component Tests See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 4806 Vacuum Brake Booster: Service and Repair Brake Booster Removal and Installation 1. NOTICE: 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. 3. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch. Remove the stoplamp switch. 4. 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 DTCs being set. Disconnect the brake booster solenoid electrical connector. 5. 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. 6. Disconnect the brake booster rod from the brake pedal and position aside. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Testing and Inspection > Page 4807 7. Remove and discard the 4 brake booster nuts and the booster. - To install, tighten the new nuts to 22 Nm (16 lb-ft). 8. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch. This switch must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any other position will result in incorrect adjustment and may damage the switch. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Locations > Page 4812 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4817 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4818 Electronic Brake Control Module: Diagrams Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4819 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 4820 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation NOTICE: Electronic modules are sensitive to electrical charges. The Anti-lock Brake System (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 Programmable Module Installation in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control Unit (HCU) See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair. 2. Remove the 4 screws and the ABS module. - To install, tighten to 2 Nm (18 lb-in). 3. NOTICE: Make sure that the Anti-lock Brake System (ABS) module is properly seated to the Hydraulic Control Unit (HCU) and that the torque of the ABS module screws is correct, or damage to the components can occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Locations > Page 4824 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS Sensor Block > Component Information > Locations > Page 4829 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair Acceleration/Deceleration Sensor: Service and Repair Stability Control Sensor Cluster Removal and Installation NOTE: When installing a new stability control sensor cluster, the ABS module must be calibrated. Follow the scan tool directions for the calibration procedures. 1. Remove the pin-type retainer and the LH floor console finish panel. 2. Remove the 2 bolts, 2 nuts and the LH instrument panel brace. - To install, tighten to 9 Nm (80 lb-in). 3. Remove the 2 bolts and LH floor 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration/Deceleration Sensor > Component Information > Service and Repair > Page 4833 - To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations Brake Booster Vacuum Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4837 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Page 4838 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4842 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 4843 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4847 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 4848 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor Removal and Installation 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 screws and the steering wheel rotation sensor. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 4855 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 4856 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 lb-in). 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 center finish panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4861 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4862 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4863 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4864 Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4865 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4866 Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 4867 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4870 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4871 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 4872 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 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. - To install, tighten to 8 Nm (71 lb-in). 4. Remove the wheel speed sensor harness pin-type retainers. 5. Remove the wheel speed sensor bolt and the wheel speed sensor. - To install, tighten the bolt to 17 Nm (150 lb-in). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4875 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 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 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4876 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring - Rear Wheel Speed Sensor Ring - Rear Removal 1. Remove the rear halfshaft. 2. Using a suitable driver, remove the ABS wheel speed sensor ring. Installation 1. Install the new ABS wheel speed sensor and the Wheel Speed Sensor Ring Installers on the halfshaft as shown. 2. Using the Wheel Speed Sensor Ring Installers, install the ABS wheel speed sensor ring as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 4877 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Lock Cylinder - Functional 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. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys must be programmed. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4885 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Lock Cylinder - Non Functional Removal 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. 3. Program the new PATS keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4889 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4890 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Starter Relay > Page 4896 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay Starter Relay: Testing and Inspection Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4899 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4900 Starter Relay: Testing and Inspection Run/Start Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4901 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair Battery Cables - 4.0L Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 4906 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery. For additional information, refer to Battery Disconnect See: Service and Repair/Battery Disconnect. 3. Remove the starter solenoid terminals protective cap. 4. Remove the starter solenoid wire cable terminal nut. - To install, tighten to 6 Nm (53 lb-in). 5. Remove the starter solenoid positive cable terminal nut. - To install, tighten to 12 Nm (106 lb-in). 6. Disconnect the starter solenoid wire cable terminal. 7. Disconnect the starter solenoid positive cable terminal. 8. Remove the nut and disconnect the starter motor ground cable terminal. - To install, tighten to 25 Nm (18 lb-ft). 9. Disconnect the power steering pressure switch electrical connector. 10. Disconnect the A/C compressor electrical connector. 11. Disconnect the oil pressure sending unit electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 4907 12. Remove the nut and position the battery cable engine front cover bracket aside. - To install, tighten to 20 Nm (177 lb-in). 13. Remove the nut and position the battery cable frame bracket aside. - To install, tighten to 9 Nm (80 lb-in). 14. Release the battery cable harness locators from the front of the engine. 15. Disconnect the 2 generator electrical connectors. 16. Position the protective cover aside, remove the nut and position the generator B+ terminal aside. - To install, tighten to 17 Nm (150 lb-in). 17. Release the battery cable harness locator from the generator harness guide. 18. Open the Battery Junction Box (BJB) cover and remove the 2 BJB nuts. - To install, tighten to 9 Nm (80 lb-in). 19. Disconnect the BJB terminal. 20. Remove the nut and position the battery cable body ground terminal aside. - To install, tighten to 9 Nm (80 lb-in). 21. Remove the 2 battery cable harness locators from the battery tray. 22. Disconnect the battery cable harness electrical connector. 23. Remove the battery cables. 24. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 4913 Alternator: Mechanical Specifications General Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4914 Alternator: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4915 Alternator: Description and Operation Charging System The charging system is a negative ground system consisting of: - a generator. - an internal voltage regulator. - a charging system warning indicator. - a battery. - circuitry and cables. - a PCM. The generator is driven by the accessory drive belt. When the engine is started, the generator begins to generate AC which is internally converted to DC. The DC is controlled by the voltage regulator (located on the rear of the generator) and supplied to the battery. The PCM controls the voltage regulation set point, working with the generator internal voltage regulator over 2 control and communication circuits. The generator and voltage regulator: - supply current to the electrical system. - charge the battery. - adjust the generator field current to increase or decrease the generator output. - have a PCM-controlled warning lamp. - output is controlled by the PCM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4916 Alternator: Service and Repair Generator - 4.0L SOHC Removal and Installation 1. Disconnect the battery. 2. Rotate the Front End Accessory Drive (FEAD) belt tensioner counterclockwise and position the FEAD belt aside. 3. Position the protective cover aside and remove and discard the generator B+ terminal nut. - To install, tighten to 17 Nm (150 lb-in). 4. Disconnect the generator B+ terminal and the 2 electrical connectors. 5. Remove the 3 bolts and the generator. - To install, tighten to 47 Nm (35 lb-ft). 6. If necessary, remove the nut and the generator pulley. - To install, tighten to 109 Nm (80 lb-ft). 7. If necessary, remove the cap and nut and position the radial adapter aside. - To install, tighten to 11 Nm (97 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4917 8. To install, reverse the removal procedure. - Install a new generator B+ terminal nut. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional Ignition Lock Cylinder - Functional 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. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. With the ignition switch in the RUN position, press the locking pin with a suitable tool and remove the ignition lock cylinder. 2. If a new lock cylinder with keys is replaced, the new Passive Anti-Theft System (PATS) keys must be programmed. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 4924 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional Ignition Lock Cylinder - Non Functional Removal 1. Remove the Passive Anti-Theft System (PATS) transceiver. 2. Remove the ignition lock cylinder. - Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. - Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the ignition lock cylinder breaks loose. - Remove and discard the ignition lock cylinder and drill shavings from the steering column. 3. Remove the bearing retainer. 4. Remove the steering column lock housing bearing and steering column lock gear. Installation 1. Thoroughly clean all drill shavings from the steering column and inspect it for damage. 2. Install a new ignition lock cylinder. - Verify the ignition lock cylinder operation. 3. Program the new PATS keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control Key: Testing and Inspection Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure will not function. This switch is set to ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures. 1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is ENABLED, when viewing the IC PID SPAREKEY. From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - the spare key programming procedure is not accessible. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4929 Key: Testing and Inspection Key Programming Using Diagnostic Equipment Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle will not start until a minimum of 2 keys are programmed into the Instrument Cluster (IC). NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be available to carry out this procedure. One or both of them may be the customer's original keys. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Turn the key to the OFF position and disconnect the scan tool. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. The vehicle should now start with both PATS ignition keys. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4930 Key: Testing and Inspection Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch; ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC during this programming procedure, but only if the IC PID SPAREKEY is ENABLED. NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure will end. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2 keys have been programmed), no matter how many keys are programmed to the vehicle. 1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder. 3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 4. Turn the key to the OFF position and remove the key from the ignition lock cylinder. 5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new key) into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), repeat Steps 1-5 for each additional key that needs to be programmed. 7. Start the vehicle with the new key(s). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4931 Key: Testing and Inspection Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder(s). NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed into all of their vehicles keys (or, to all of the keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle) need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is turned on, and must be turned off before viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the on-screen instructions. 5. Select: "unlimited key mode ON" and follow the on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to be removed at this time). 8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON position for 3 seconds. 9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 11. The vehicle should now start with both PATS keys. 12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4932 NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need to be removed at this time). 5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the Instrument Cluster (IC) using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be enabled. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4933 Key: Testing and Inspection Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure will not function. This switch is set to ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures. 1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is ENABLED, when viewing the IC PID SPAREKEY. From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - the spare key programming procedure is not accessible. Key Programming Using Diagnostic Equipment Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle will not start until a minimum of 2 keys are Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4934 programmed into the Instrument Cluster (IC). NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be available to carry out this procedure. One or both of them may be the customer's original keys. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Turn the key to the OFF position and disconnect the scan tool. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. The vehicle should now start with both PATS ignition keys. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch; ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC during this programming procedure, but only if the IC PID SPAREKEY is ENABLED. NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4935 Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure will end. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2 keys have been programmed), no matter how many keys are programmed to the vehicle. 1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder. 3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 4. Turn the key to the OFF position and remove the key from the ignition lock cylinder. 5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new key) into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), repeat Steps 1-5 for each additional key that needs to be programmed. 7. Start the vehicle with the new key(s). Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder(s). NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed into all of their vehicles keys (or, to all of the keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle) need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is turned on, and must be turned off before viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It should not be the same key code. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4936 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the on-screen instructions. 5. Select: "unlimited key mode ON" and follow the on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to be removed at this time). 8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON position for 3 seconds. 9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 11. The vehicle should now start with both PATS keys. 12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need to be removed at this time). 5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the Instrument Cluster (IC) using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be enabled. Spare Key Programming - Using Diagnostic Equipment Spare Key Programming - Using Diagnostic Equipment Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4937 NOTE: This procedure is used when a customer needs to have an additional key programmed into the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This procedure is also useful when attempting to determine if an ignition key is damaged, as a new key can be installed without erasing keys or without having 2 programmed keys available. NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock cylinder. NOTE: If 8 keys are already programmed, this procedure does not allow any more ignition keys to be programmed. The number of keys that are programmed into the Passive Anti-Theft System (PATS) can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2 keys have been programmed), no matter how many keys are programmed to the vehicle. 1. Turn the unprogrammed PATS key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: Make sure the selection made is "PROGRAM" (Program additional ignition key). If the "ERASE" (Ignition Key Code Erase) selection is made, all of the keys will be erased from the system. From the scan tool menu select: "Program additional ignition key" and follow the on-screen instructions. 4. Turn the key to the OFF position and disconnect the scan tool. 5. Start the vehicle with the new PATS key. The vehicle will now start with the new PATS key and also with the original PATS keys. Passive Anti-Theft System (PATS) Parameter Reset Passive Anti-Theft System (PATS) Parameter Reset NOTE: When using the Integrated Diagnostic System (IDS), the Instrument Cluster (IC) and the PCM parameters are reset at the same time. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics . 3. From the scan tool, select: Parameter Reset and follow the on-screen instructions. 4. NOTE: If the IC was replaced, follow Steps 4-9. If the IC and the PCM were replaced, follow Steps 4-9. If only the PCM was replaced, go to Step 9. From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 4938 5. Turn the key to the OFF position and disconnect the scan tool. 6. Turn the key to the ON position for a minimum of 3 seconds. 7. Turn the key to the OFF position and remove the key. 8. Insert the second key into the ignition lock cylinder and turn the key to the ON position for a minimum of 3 seconds. 9. Both keys will now start the vehicle. 10. If more keys are required to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Neutral Safety Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4942 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4943 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > General Specifications Starter Motor: Specifications General Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > General Specifications > Page 4948 Starter Motor: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4949 Starter Motor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4950 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4951 Starter Motor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4952 Starter Motor: Service and Repair Starter Motor - 4.0L SOHC Removal and Installation WARNING: Always disconnect the battery ground cable at the battery before disconnecting the starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the starter motor solenoid terminal cover. 4. Remove the B-terminal nut and disconnect the cable. - To install, tighten to 12 Nm (106 lb-in). 5. Remove the S-terminal nut and disconnect the cable. - To install, tighten to 6 Nm (53 lb-in). 6. Remove the nut and position the ground cable aside. - To install, tighten to 20 Nm (177 lb-in). 7. Remove the bolt, the stud bolt and the starter. - To install, tighten to 25 Nm (18 lb-ft). 8. To install, reverse the removal procedure. - Tighten the upper bolt before tightening the lower fastener. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Starter Relay > Page 4957 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay Starter Relay: Testing and Inspection Starter Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4960 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4961 Starter Relay: Testing and Inspection Run/Start Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection > Starter Relay > Page 4962 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 4968 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 4969 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 4970 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point Auxiliary Power Outlet: Service and Repair Pickup Bed Power Point Pickup Bed Power Point Removal and Installation 1. Remove the 4 screws and the power point receptacle from the pickup bed side. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 4973 Auxiliary Power Outlet: Service and Repair Power Point Power Point Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the Power Point Socket Remover in one of the power point socket slots. 3. Position the Power Point Socket Remover so that it engages in the adjacent slot. 4. Using the Power Point Socket Remover, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4977 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4978 Circuit Breaker: Application and ID Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 4979 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 4984 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 4985 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4990 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4991 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4992 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4993 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4994 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4995 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4996 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4997 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4998 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 4999 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 5002 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5003 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5004 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5005 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5006 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 (V6-4.0L (2009)) 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 5007 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5008 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5009 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5010 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5011 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) Fuse Block: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5016 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5017 Fuse Block: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5018 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5019 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5020 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5021 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5022 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5025 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5026 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5027 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5028 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5029 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5030 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5031 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5032 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5033 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5034 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5035 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5036 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5037 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5038 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5039 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5040 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5041 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5042 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5043 Fuse Block: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5044 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5045 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5046 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5049 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5053 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5057 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 Multiple Junction Connector: Diagrams C110-C410 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5062 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5063 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5064 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5065 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5066 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5067 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5068 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5069 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5070 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5071 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5072 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5073 Part 3 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5074 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5075 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5076 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5077 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5078 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5079 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5080 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5081 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5082 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5083 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5084 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5085 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5086 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5087 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5088 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5089 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5090 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5091 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5092 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5093 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5094 Multiple Junction Connector: Diagrams C411-C4004 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5095 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5096 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5097 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5098 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5099 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5100 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5101 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5102 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5103 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5104 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5105 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5106 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5107 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5108 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5109 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5110 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5111 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5112 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5113 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5114 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5115 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5116 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5117 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5118 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5119 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5120 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5124 NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. 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. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. 9. 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. 10. NOTICE: 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 (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11. If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. 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 Remote Keyless Entry (RKE) transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower right SJB bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5125 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 (177 lb-in). 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. 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. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. NOTE: When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. Download the SJB configuration information from the scan tool into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming 15. 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. 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5129 Power Distribution Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5130 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5131 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5136 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5140 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5144 NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. 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. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. 9. 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. 10. NOTICE: 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 (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11. If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. 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 Remote Keyless Entry (RKE) transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower right SJB bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5145 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 (177 lb-in). 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. 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. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. NOTE: When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. Download the SJB configuration information from the scan tool into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming 15. 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. 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5149 Power Distribution Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5151 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) Relay Box: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5156 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5157 Relay Box: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5158 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5159 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5160 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5161 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5162 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5165 Relay Box: Diagrams Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5166 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5167 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5168 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5169 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5170 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5173 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5174 Relay Box: Application and ID Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5175 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) Relay Box: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5180 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5181 Relay Box: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5182 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5183 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5184 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5185 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5186 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5189 Relay Box: Diagrams Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5190 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5191 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5192 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5193 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5194 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5197 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5198 Relay Box: Application and ID Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5199 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5205 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5206 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Power Point, Rear > Page 5207 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point Auxiliary Power Outlet: Service and Repair Pickup Bed Power Point Pickup Bed Power Point Removal and Installation 1. Remove the 4 screws and the power point receptacle from the pickup bed side. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > Pickup Bed Power Point > Page 5210 Auxiliary Power Outlet: Service and Repair Power Point Power Point Removal NOTE: Power point cover may differ depending on location. 1. Open the power point cover. 2. Install the Power Point Socket Remover in one of the power point socket slots. 3. Position the Power Point Socket Remover so that it engages in the adjacent slot. 4. Using the Power Point Socket Remover, pull the power point socket out of the retainer. 5. Disconnect the electrical connector. Installation 1. Connect the electrical connector. 2. Slide the power point socket into the retainer. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5214 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5215 Circuit Breaker: Application and ID Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 5216 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 5221 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Diagrams > Ignition Transformer Capacitor 1 > Page 5222 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5227 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5228 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5229 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5230 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5231 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5232 Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5233 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5234 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5235 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5236 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5239 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5240 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5241 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5242 Passenger Compartment Fuse Panel / Smart Junction Box (SJB) Side View Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5243 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5244 Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box Location Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5245 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5246 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5247 Fuse Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Passenger Compartment Fuse Panel / Smart Junction Box (SJB) > Page 5248 Battery Junction Box (BJB) / Power Distribution Box Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) Fuse Block: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5253 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5254 Fuse Block: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5255 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5256 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5257 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5258 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery Junction Box (BJB) > Page 5259 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5271 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5272 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5273 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5274 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5275 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5276 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5277 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5278 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5279 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5280 Fuse Block: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5281 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5282 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5283 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5284 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5285 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5286 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5290 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5294 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 Multiple Junction Connector: Diagrams C110-C410 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5299 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5300 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5301 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5302 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5303 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5304 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5305 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5306 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5307 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5308 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5309 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5310 Part 3 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5311 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5312 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5313 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5314 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5315 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5316 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5317 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5318 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5319 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5320 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5321 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5322 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5323 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5324 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5325 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5326 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5327 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5328 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5329 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5330 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5331 Multiple Junction Connector: Diagrams C411-C4004 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5332 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5333 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5334 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5335 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5336 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5337 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5338 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5339 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5340 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5341 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5342 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5343 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5344 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5345 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5346 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5347 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5348 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5349 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5350 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5351 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5352 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5353 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5354 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5355 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5356 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C110-C410 > Page 5357 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5361 NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. 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. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. 9. 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. 10. NOTICE: 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 (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11. If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. 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 Remote Keyless Entry (RKE) transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower right SJB bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5362 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 (177 lb-in). 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. 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. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. NOTE: When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. Download the SJB configuration information from the scan tool into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming 15. 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. 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5366 Power Distribution Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5367 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5368 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 5373 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 5377 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair Power Distribution Module: Service and Repair Smart Junction Box (SJB) Removal Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5381 NOTICE: If the SJB is dropped, damage to the internal components may occur. A new SJB must be installed. NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information into the appropriate scan tool. This information must be downloaded into the new module after installation. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. 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 a manufacturing mode with 6 pre-set DTCs related to the TPMS. To clear the DTCs, successful configuration of the SJB must occur, followed by successful TPMS sensor training, and a successful self-test, including clearing of the DTCs. The DTCs are as follows: - B2477 (Module Configuration Failure) - B2868 (Left Front Tire Pressure Sensor Fault) - B2869 (Right Front Tire Pressure Sensor Fault) - B2870 (Right Rear Tire Pressure Sensor Fault) - B2871 (Left Rear Tire Pressure Sensor Fault) - C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is necessary only if the SJB is being replaced. Upload the module configuration information from the SJB. 2. Remove the driver door scuff plate. 3. Position the LH door opening weather seal aside. 4. 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. 5. Remove the 2 bolts and the parking brake release handle. 6. Disconnect the parking brake switch electrical connector. 7. Release the hood release cable pushpin from the parking brake control bracket. 8. Release the harness clip from the parking brake cable housing. 9. 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. 10. NOTICE: 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 (then lift it upward to disengage the lower tangs from the instrument panel), disconnect the 2 electrical connectors and position the bezel assembly aside. 11. If necessary, push the LH instrument panel side finish panel out and position it aside. 12. Through the headlight switch bezel opening, remove the 2 SJB bolts. 13. From under the instrument panel, remove the third (lower right) SJB bolt. 14. 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 Remote Keyless Entry (RKE) transmitters may be required to be present in order to program the RKE transmitters to the new SJB. 1. Position the SJB into the 2 locating pins and connect the 5 electrical connectors. 2. From under the instrument panel, install the lower right SJB bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Page 5382 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 (177 lb-in). 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. 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. 12. Position the LH door opening weather seal. 13. NOTE: If the SJB was not replaced, this is the last step that is necessary. Install the driver door scuff plate. 14. NOTE: When successful, this step provides the calibration necessary for the SJB operation and clears DTC B2477. The clearing of this DTC indicates the calibration data has been successfully downloaded to the new SJB. NOTE: When successful, this step also programs the remote transmitters into the new SJB. In the event the remote transmitters do not program to the new SJB, all of the remote transmitters will need to be present and refer to Locks, Remote Keyless Entry Transmitter Programming. This action will program the remote transmitters into the new SJB. Download the SJB configuration information from the scan tool into the new SJB. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Testing and Inspection/Remote Keyless Entry (RKE) Transmitter Programming 15. 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. 16. NOTE: DTC C2780 will not clear if any of the pre-set DTCs are still present in the SJB. When successful, this step will clear DTC C2780. Carry out the SJB self-test (must include an on-demand) by clearing DTCs, and then retrieving DTCs to confirm all DTCs have been cleared. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5386 Power Distribution Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5387 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 5388 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) Relay Box: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5393 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5394 Relay Box: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5395 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5396 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5397 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5398 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5399 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5402 Relay Box: Diagrams Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5403 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5404 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5405 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5406 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5407 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5410 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5411 Relay Box: Application and ID Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5412 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) Relay Box: Locations Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5417 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5418 Relay Box: Locations Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5419 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5420 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5421 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5422 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 5423 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5426 Relay Box: Diagrams Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5427 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5428 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5429 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5430 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Battery Junction Box (BJB) > Page 5431 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) Relay Box: Application and ID Battery Junction Box (BJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5434 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5435 Relay Box: Application and ID Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 5436 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications Alignment: Specifications Alignment Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 5442 Alignment: Specifications Ball Joint Deflection, Ride Height, Thrust Angle, and Vehicle Lean Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 5443 Alignment: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber Alignment: Description and Operation Camber 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 flagnut with a non-flagnut 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5446 Alignment: Description and Operation Caster 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 flagnut with a non-flagnut 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5447 Alignment: Description and Operation Drift/Pull 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 flagnut with a non-flagnut 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5448 Alignment: Description and Operation Nibble 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 flagnut with a non-flagnut 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5449 Alignment: Description and Operation Camber 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 flagnut with a non-flagnut 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 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 flagnut with a non-flagnut 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. 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. Drift/Pull 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 flagnut with a non-flagnut 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5450 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. Nibble 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 flagnut with a non-flagnut 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. 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 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 flagnut with a non-flagnut 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. 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. Shimmy 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 flagnut with a non-flagnut 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. 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. Toe 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 flagnut with a non-flagnut 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. Toe Positive Toe (Toe In) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Camber > Page 5451 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. Incorrect Thrust Angle (Dogtracking) Wander 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 flagnut with a non-flagnut 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 following 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 lb-ft). 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 arm rearward nut. 6. Position the LF lower 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 arm rearward nut to 200 Nm (148 lb-ft). 8. Recheck the camber and caster, adjust as necessary. 9. Check and, if necessary, adjust the front toe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 5454 Alignment: Service and Repair Ride Height Measurement Ride Height Measurement Front Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and adjust the gauge arm until the scriber point is located in the center of the lower arm inboard bolt. Lock the surface gauge in this position. 2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 2). 3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge arm until the scriber point is located in the center of the shock absorber lower bolt. Lock the surface gauge in this position. 4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface gauge position (measurement 3). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 5455 5. Subtract measurement 3 from measurement 2 to obtain the front ride height. - Refer to Specifications. Rear Ride Height Measurement NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure. Vehicle should have a full tank of fuel. 1. Measure the distance between the flat level surface and the center of the lower arm inboard bolt (measurement 2). 2. Measure the distance between the flat level surface and the center of the shock absorber lower bolt (measurement 3). 3. Subtract measurement 3 from measurement 2 to obtain the rear ride height. - Refer to Specifications. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 5456 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. 6. Rotate the front wheel inner tie rods until the toe setting is within specification. 7. NOTICE: 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 lb-ft). 8. Install the clamps. 9. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 5457 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 lb-ft). 7. Recheck the toe settings and adjust if necessary. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and Caster Adjustment - Front > Page 5458 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 flagnut must be removed and replaced with a non-flagnut 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. 3. Using alignment equipment and the manufacturer's instructions, measure the rear camber. 4. 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 in) 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. 5. NOTE: Make sure that the camber settings are not disturbed while tightening the nut. Tighten the upper arm inboard nut to 250 Nm (185 lb-ft). 6. Recheck the camber settings and adjust as necessary. 7. Check and, if necessary, adjust the rear toe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5464 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 EPC pressure during increased engine load, for example during parking maneuvers. Typical Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5467 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Engine Control Components 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 EPC pressure during increased engine load, for example, during parking maneuvers. Typical Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5471 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5472 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5477 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5478 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training 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). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning. 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. 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training > Page 5484 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. 8. 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. 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. 10. 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. 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 (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training > Page 5485 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. For additional information, refer to Wheel and Tire See: Wheels and Tires/Service and Repair/Overhaul. 2. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. 3. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5488 4. Remove the sensor. Assembly 1. NOTICE: Damage to the sensor may 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. 3. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire See: Wheels and Tires/Service and Repair/Overhaul. 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 See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5489 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor See: Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5490 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory-installed strap in the following 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 in) from the buckle. 2. Using a large screwdriver and a twisting motion, unbuckle the strap. 3. Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. - Discard the strap. 4. 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. NOTICE: Metal scrapers may 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. Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed. 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 degrees from the valve stem. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5491 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. NOTICE: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. 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 in) away from the sensor and tighten the worm gear. - Tighten to 3 Nm (27 lb-in). 6. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire. See: Wheels and Tires/Service and Repair/Overhaul 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. See: Wheels and Tires/Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5496 Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 and tire. 2. Remove and discard the halfshaft nut. - To install, tighten to 250 Nm (184 lb-ft). 3. Using the Front Wheel Hub Remover, separate the outboard CV joint from the wheel hub. 4. NOTICE: 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 lb-ft). 5. Remove the brake disc. 6. Remove the wheel speed sensor harness bracket bolt from the wheel knuckle. - To install, tighten to 8 Nm (71 lb-in). 7. Disconnect the wheel speed sensor harness pin-type retainers. 8. Disconnect the wheel speed sensor electrical connector. 9. Remove and discard the tie-rod end nut. - To install, tighten the new nut to 103 Nm (76 lb-ft). 10. NOTICE: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the tie-rod boot while installing the C-Frame and Screw. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 5497 Using the C-Frame and Screw, separate the tie-rod end from the wheel knuckle. 11. Remove and discard the lower ball joint nut. - To install, tighten the new nut to 150 Nm (111 lb-ft). 12. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the 2-Jaw Puller. Using the 2-Jaw Puller, separate the lower ball joint from the wheel knuckle. 13. Remove and discard the upper ball joint nut. - To install, tighten the new nut to 55 Nm (41 lb-ft). 14. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw. Using the C-Frame and Screw, separate the upper ball joint and remove the wheel knuckle. 15. To install, reverse the removal procedure. - Check and if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTICE: If the air is not purged from the power steering system correctly, premature power steering pump failure may result. The condition may 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 reservoir cap. Check the fluid. 2. Raise the front wheels off the floor. 3. Tightly insert the Power Steering Evacuation Cap into the reservoir and connect the Vacuum Pump Kit. 4. Start the engine. 5. Using the Vacuum Pump Kit, apply vacuum and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg). - If the Vacuum Pump Kit does not maintain vacuum, check the power steering system for leaks before proceeding. For additional information, refer to Power Steering Fluid Leak Test. See: Testing and Inspection/Component Tests and General Diagnostics/Power Steering Fluid Leak Test 6. If equipped with Hydro-Boost(R), apply the brake pedal 4 times. 7. NOTICE: Do not hold the steering wheel against the stops for an extended amount of time. Damage to the power steering pump may occur. Cycle the steering wheel fully from stop-to-stop 10 times. 8. Stop the engine. 9. Release the vacuum and remove the Vacuum Pump Kit and the Power Steering Evacuation Cap. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 5502 10. NOTE: Do not overfill the reservoir. Fill the reservoir. - Use approved transmission fluid. 11. Start the engine. 12. Install the Power Steering Evacuation Cap and the Vacuum Pump Kit. Apply and maintain the maximum vacuum of 68-85 kPa (20-25 in-Hg). 13. NOTICE: Do not hold the steering wheel against the stops for an extended amount of time. Damage to the power steering pump may occur. Cycle the steering wheel fully from stop-to-stop 10 times. 14. Stop the engine, release the vacuum and remove the Vacuum Pump Kit and the Power Steering Evacuation Cap. 15. NOTE: Do not overfill the reservoir. Fill the reservoir as needed and install the reservoir cap. 16. Visually inspect the power steering system for leaks. 17. NOTE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications Power Steering Fluid Type Ford Part Name ................................................................................................................................... ................................ Motorcraft MERCON V ATF Ford Part Number ................................................. ............................................................................................................................................. XT-5-QM Ford Specification ................................................................................................................................ ......................................................... MERCON V Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: 4.0L engine shown, 4.6L engine similar. Removal and Installation NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the power steering fluid cooler clamp and disconnect the fluid cooler from the fluid reservoir. 3. Remove the LH front splash shield screws, pin-type retainers and the splash shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 5509 4. Remove the lower radiator air deflector pushpins and the air deflector. 5. Remove the 2 power steering fluid cooler hose braces. 6. Remove the power steering fluid cooler hose bracket bolt. - To install, tighten to 18 Nm (159 lb-in). 7. Remove the steering line clamp plate nut. - To install, tighten to 25 Nm (18 lb-ft). 8. Rotate the steering line clamp plate and disconnect the power steering fluid cooler 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 power steering pressure and fluid cooler line is disconnected from the steering gear. To install, reverse the removal procedure. 11. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: 4.0L engine shown, 4.6L engine similar. Removal and Installation NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. Using a suitable suction device, remove the power steering fluid from the reservoir. 2. Remove the power steering fluid reservoir bolt. - To install, tighten to 9 Nm (80 lb-in). 3. Release the power steering pump supply hose clamp and disconnect the hose. 4. Release the power steering fluid cooler hose clamp and disconnect the hose. 5. Remove the power steering fluid reservoir. 6. To install, reverse the removal procedure. 7. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: 4.6L engine shown, 4.0L engine similar. Removal NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Page 5516 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0L See: Power Steering Pump/Service and Repair/Power Steering Pump Pulley or Power Steering Pump Pulley - 4.6L See: Power Steering Pump/Service and Repair/Power Steering Pump Pulley. 3. Remove the steering line clamp plate nut. 4. Rotate the steering line clamp plate and disconnect the power steering fluid cooler 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). 7. Remove the pressure line bracket-to-crossmember bolt. 8. Disconnect the pressure line-to-pump fitting. - Remove and discard the Teflon(R) seal. 9. Remove the pressure line. Installation 1. NOTE: A new Teflon(R) seal must be installed. Using the Teflon(R) Seal Installer Set, install a new Teflon(R) seal on the pressure line fitting. 2. Position the pressure line and connect the pressure line-to-pump fitting. - Tighten to 65 Nm (48 lb-ft). 3. Install the pressure line bracket-to-engine nut (4.6L) or bolt (4.0L). - Tighten to 11 Nm (97 lb-in). 4. NOTE: New O-rings must be installed whenever the pressure line and fluid cooler are disconnected from the steering gear. 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 (106 lb-in). 6. Install a new O-ring seal and position the power steering fluid cooler 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 lb-ft). 8. Install the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0L See: Power Steering Pump/Service and Repair/Power Steering Pump Pulley or Power Steering Pump Pulley - 4.6L See: Power Steering Pump/Service and Repair/Power Steering Pump Pulley. 9. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 - 4.0L Removal NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. Using a suitable suction device, remove the power steering fluid from the reservoir. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5521 2. With the vehicle in NEUTRAL, position it on a hoist. 3. Remove the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0L See: Power Steering Pump Pulley. 4. Remove the pressure line bracket-to-engine bolt. 5. Remove the power steering pump supply hose bracket bolt. 6. Release the power steering pump supply hose clamp and disconnect the hose. 7. Disconnect the pressure line-to-pump fitting. - Remove and discard the Teflon(R) seal. 8. Remove the 3 bolts and the power steering pump. Installation 1. NOTE: A new Teflon(R) seal must be installed. Using the Teflon(R) Seal Installer Set, install a new Teflon(R) seal to the pressure line fitting. 2. Position the power steering pump and install the 3 bolts. - Tighten to 25 Nm (18 lb-ft). 3. Connect the pressure line-to-pump fitting. - Tighten to 65 Nm (48 lb-ft). 4. Connect the power steering pump supply hose. 5. Install the power steering pump supply hose bracket bolt. - Tighten to 11 Nm (97 lb-in). 6. Install the pressure line bracket-to-engine bolt. - Tighten to 11 Nm (97 lb-in). 7. Install the power steering pump pulley. For additional information, refer to Power Steering Pump Pulley - 4.0L See: Power Steering Pump Pulley. 8. Fill the power steering system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 5522 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley - 4.0L Removal and Installation 1. Disconnect the fan clutch electrical connector, remove the fan clutch wiring harness bracket bolt and position the harness aside. - To install, tighten to 7 Nm (62 lb-in). 2. Loosen the 3 power steering pump pulley bolts. 3. Rotate the tensioner and remove the engine accessory drive belt from the power steering pump pulley. 4. Remove the 3 bolts and the power steering pump pulley. - To install, tighten to 25 Nm (18 lb-ft). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5527 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 EPC pressure during increased engine load, for example during parking maneuvers. Typical Power Steering Pressure (PSP) Switch Typical Power Steering Pressure (PSP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5530 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor Engine Control Components 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 EPC pressure during increased engine load, for example, during parking maneuvers. Typical Power Steering Pressure (PSP) Sensor Typical Power Steering Pressure (PSP) Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5534 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 5535 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 5539 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Locations > Page 5540 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. 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 this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagram. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition to OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5546 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5547 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the cover and RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5548 7. Remove the 2 driver air bag module bolts (1 shown). 8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Open and lower the glove compartment door. 10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield. 11. NOTE: The canister vent and adaptive tether do not require deactivation. Disconnect the LH side passenger air bag module electrical connector. 12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Disengage the passenger seat side air bag module electrical connector locking clip, release the tab and disconnect the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 13. Release and position aside the passenger side C-pillar trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5549 14. Disconnect the passenger side safety canopy module electrical connector. 15. Release and position aside the driver side C-pillar trim panel. 16. Disconnect the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 17. Remove the driver and passenger side upper C-pillar trim panels. 18. Disconnect the passenger side safety canopy module electrical connector. 19. Disconnect the driver side safety canopy module electrical connector. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5550 20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module electrical connector locking clip, release the tab and disconnect the driver seat side air bag module electrical connector. 21. Install the RCM fuse 17 (10A) to the SJB. 22. 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. 3. Connect the driver seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles 4. Connect the driver side safety canopy module electrical connector. 5. Connect the passenger side safety canopy module electrical connector. 6. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 7. Connect the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5551 8. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 11. Connect the passenger seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Attach the passenger seat side air bag module electrical connector to the seat track bracket. 12. Connect the LH side passenger air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5552 13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer. 14. NOTICE: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. 15. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 16. Turn the ignition switch from OFF to ON. 17. Install RCM fuse 17 (10A) to the SJB and install the cover. 18. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 19. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair Steering Gear: Service and Repair Steering Gear Steering Gear (View 1 of 2) Steering Gear (View 2 of 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 5556 Removal and Installation All vehicles NOTICE: While repairing the power steering system, care should be taken to prevent the entry of foreign material or failure of the power steering components may result. 1. NOTICE: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring may result. If there is evidence that the lower shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Air Bag Systems. NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position. 2. Remove the front tires and wheels. 3. If equipped, remove the 2 bolts, pin-type retainer and the oil shield. - To install, tighten to 15 Nm (133 lb-in). 4. Remove and discard the lower steering column shaft-to-steering gear bolt. - To install, tighten the new bolt to 48 Nm (35 lb-ft). 5. Disconnect the lower steering column shaft from the steering gear. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 5557 6. Remove the steering line clamp plate nut. - To install, tighten to 25 Nm (18 lb-ft). 7. Rotate the steering line clamp plate and disconnect the power steering pressure line and fluid cooler. 8. NOTE: New O-rings must be installed whenever the power steering line and fluid cooler are disconnected from the steering gear. Remove and discard the 2 O-rings. 9. Remove and discard the 2 tie-rod end nuts. - To install, tighten the new nuts to 103 Nm (76 lb-ft). 10. NOTICE: Use care when installing the C-Frame and Screw or damage to the tie-rod end boot may occur. Using the C-Frame and Screw, separate the 2 tie-rod ends from the wheel knuckle. 11. Remove the 2 steering gear-to-crossmember nuts and bolts. - To install, tighten to 350 Nm (258 lb-ft). Four-Wheel Drive (4WD) vehicles NOTE: On Four-Wheel Drive (4WD) vehicles, the following steps (LH lower arm only) must be carried out to provide clearance to remove the steering gear. 12. Remove the shock absorber lower bolt and flagnut. - Discard the flagnut. - To install, tighten to 350 Nm (258 lb-ft). 13. NOTICE: Do not tighten the LH lower arm nuts and bolts until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load or bushing damage may occur. NOTE: It is not necessary to disconnect the LH lower ball joint. Remove and discard the lower arm forward bolt and nut and the lower arm rearward flag bolt and nut. - To install the new lower arm forward bolt, tighten to 400 Nm (296 lb-ft). - To install the new lower arm rearward flag bolt and nut, tighten to 200 Nm (148 lb-ft). 14. Remove the stabilizer bar link nut and the link. - Discard the stabilizer bar link nut. - To install, tighten the new nut to 35 Nm (26 lb-ft). All vehicles 15. Remove the steering gear from the LH side of the vehicle. 16. If a new steering gear is being installed, remove the 4 steering gear bushings and the 2 nuts. 17. NOTICE: On Four-Wheel Drive (4WD) vehicles, do not tighten the LH lower arm nuts and bolts until the installation procedure is complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load bushing damage may occur. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 5558 - Install 2 new O-ring seals and new flag nuts. - Fill the power steering system. - Check and, if necessary, set the front toe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal and Installation 1. NOTICE: Do not allow the steering column to rotate while the steering column shaft is disconnected or damage to the clockspring may 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. NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position. 2. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the upper steering column shaft-to-steering column bolt. To install, tighten the new bolt to 30 Nm (22 lb-ft). 3. Remove the 3 upper steering column shaft dash seal bolts. - To install, tighten to 12 Nm (106 lb-in). 4. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the lower steering column shaft-to-upper steering column shaft bolt. To install, tighten the new bolt to 47 Nm (35 lb-ft). 5. Remove the upper steering column shaft. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Column Shaft - Upper > Page 5563 Steering Shaft: Service and Repair Steering Column Shaft - Lower Steering Column Shaft - Lower Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTICE: Do not allow the steering column shaft to rotate while the steering column 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. NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position. 3. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the lower steering column shaft-to-upper steering column shaft bolt. To install, tighten the new bolt to 47 Nm (35 lb-ft). 4. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s). Remove and discard the lower steering column shaft-to-steering gear bolt. To install, tighten the new bolt to 47 Nm (35 lb-ft). 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. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Page 5567 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations > Page 5568 Steering Wheel: Service and Repair 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. Remove the steering wheel bolt and the steering wheel. - Discard the bolt. - To install, tighten the new bolt to 40 Nm (30 lb-ft). 5. NOTICE: Do not allow the clockspring to turn from its removal position or damage to the clockspring may occur. Tape the clockspring center rotor to the outer housing to keep it from rotating. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair Tie Rod: Service and Repair Inner Tie Rod Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 5572 Removal NOTICE: 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 damage. Zip ties do not produce an airtight seal and must not be used. NOTICE: The inner ball joint grease is not compatible with water and foreign material trapped in the grease will degrade the life of the joint. NOTICE: If present, the orientation of the vent tube must be noted so the boots and vent tubes can be installed in the correct location. Incorrect venting may lead to internal component damage. 1. Remove the front tire and wheel. 2. Loosen the tie-rod end jam nut. 3. Remove and discard the tie-rod end nut. 4. NOTICE: Use care when installing the C-Frame and Screw or damage to the tie-rod end boot may occur. Using the C-Frame and Screw, 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. Using the Boot Clamp Pliers, remove and discard the outer bellows boot clamp. 8. NOTE: A new inner bellows boot clamp must be installed. Using the Boot Clamp Pliers, remove and discard the inner bellows boot clamp. 9. Remove the steering gear bellows boot. 10. NOTICE: Place the steering gear at the center position. Use an appropriate-sized crowfoot wrench 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. While holding the steering gear rack, use an appropriate-sized crowfoot wrench to remove the inner tie rod. 11. NOTICE: 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. NOTICE: Place the steering gear at the center position. Use an appropriate-sized crowfoot wrench on the flat of the rack gear to resist rotation and to prevent damage during the installation of the inner tie rod. NOTE: An assistant may be needed for installation of the RH inner tie rod. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Page 5573 Using an appropriate-sized crowfoot wrench, install the inner tie rod. - Tighten to 100 Nm (74 lb-ft). 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. 3. Using the Boot Clamp Pliers, install a new inner bellows boot clamp. 4. 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. 5. Thread the tie-rod end jam nut onto the inner tie rod. 6. 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. 7. Tighten the tie-rod end jam nut. - Tighten to 80 Nm (59 lb-ft). 8. Position the tie-rod end to the wheel knuckle and install a new tie-rod end nut. - Tighten to 103 Nm (76 lb-ft). 9. Check and, if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 in) Upper.............................. .............................................................................................................................................................. .........0-0.2 mm (0-0.008 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) Control Arm: Service and Repair Front Suspension - rear wheel drive (RWD) Lower Arm Lower Arm Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5582 Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as when removed or incorrect clamp load and damage to components may occur. 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 the wheel and tire. 3. Remove and discard the lower ball joint nut. 4. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the 2-Jaw Puller. Using the 2-Jaw Puller, separate the lower ball joint from the wheel knuckle. 5. Remove and discard the stabilizer bar link nut and grommet. 6. Remove the stabilizer bar link. 7. Remove and discard the shock absorber lower bolt and flag nut. 8. Remove and discard the lower arm forward nut and bolt. 9. Remove the lower arm rearward nut and bolt and the lower control arm. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5583 - Discard the nut and bolt. Installation NOTICE: 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). This will prevent incorrect clamp load and bushing damage. 1. NOTE: Do not tighten the bolt at this time. Position the lower arm and install the new lower arm rearward bolt and nut. 2. NOTE: Do not tighten the bolt at this time. Install the new lower arm forward bolt and nut. 3. NOTE: Do not tighten the bolt at this time. Install the new shock absorber lower bolt and flag nut. 4. Position the stabilizer bar link and install the new nut. - Tighten the nut to 35 Nm (26 lb-ft). 5. Connect the lower ball joint to the wheel knuckle and install the new lower ball joint nut. - Tighten to 150 Nm (111 lb-ft). 6. Using a suitable jack, 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). 7. Tighten the shock absorber lower bolt to 350 Nm (258 lb-ft). 8. Tighten the lower arm forward nut to 400 Nm (296 lb-ft). 9. Tighten the lower arm rearward nut to 200 Nm (148 lb-ft). 10. Install the wheel and tire. 11. Check and if necessary, align the front end. Upper Arm Upper Arm Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5584 Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. 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 the wheel and tire. 3. Using a suitable jack support the lower control arm near the lower ball joint. 4. Remove and discard the upper ball joint nut. 5. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw. Using the C-Frame and Screw, separate the upper ball joint from the wheel knuckle. 6. Using a plastic tie strap, support the suspension at the wheel knuckle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5585 7. Remove and discard the 2 upper arm bolts and flag nuts and remove the upper arm. Installation NOTICE: 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). This will prevent incorrect clamp load and bushing damage. 1. NOTE: Do not tighten the bolt at this time. Position the upper arm and install the 2 new upper arm bolts and flag nuts. 2. Remove the plastic tie strap. 3. Connect the upper ball joint to the wheel knuckle and install the new upper ball joint nut. - Tighten to 55 Nm (41 lb-ft). 4. Using a suitable jack, 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). 5. Tighten the 2 upper arm bolts to 150 Nm (111 lb-ft). 6. Install the wheel and tire. 7. Check and if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5586 Control Arm: Service and Repair Front Suspension Lower Arm Lower Arm Removal and Installation For additional information, refer to Front Suspension - Rear Wheel Drive (RWD). See: Front Suspension - rear wheel drive (RWD)/Lower Arm Upper Arm Upper Arm Removal and Installation For additional information, refer to Front Suspension - Rear Wheel Drive (RWD). See: Front Suspension - rear wheel drive (RWD)/Upper Arm Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5587 Control Arm: Service and Repair Rear Suspension Lower Arm Lower Arm Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed, or incorrect clamp load and component damage may occur. 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 the wheel and tire. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5588 is equal to the measurement taken in Step 1. 4. Remove and discard the lower arm outboard bolt and flagnut. 5. Remove the stabilizer bar link nut and grommet and the stabilizer bar link. - 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. NOTE: 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. NOTE: 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 and a new nut and grommet. - Tighten to 30 Nm (22 lb-ft). 5. Install a new lower arm outboard bolt and flagnut. - Tighten the bolt to 275 Nm (203 lb-ft). 6. Tighten the lower arm inboard bolt to 250 Nm (185 lb-ft). 7. Tighten the shock absorber lower bolt to 275 Nm (203 lb-ft). 8. Lower the suspension and remove the jack. 9. Install the wheel and tire. Upper Arm Upper Arm Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Suspension - rear wheel drive (RWD) > Page 5589 Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed, or incorrect clamp load and component damage may occur. 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 the wheel and tire. 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 flagnut. This flagnut is used to set and maintain the rear camber settings. Discard the flagnut and install a non-flagnut to allow the rear camber to be adjusted. Remove and discard the upper arm inboard bolt and flagnut and remove the upper arm. Installation 1. Position the upper arm and install a new inboard bolt and non-flagnut. - Tighten to 250 Nm (185 lb-ft). 2. NOTICE: 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 225 Nm (166 lb-ft). 3. Lower the suspension and remove the jack. 4. Check and, if necessary, align the rear end. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications Cross-Member: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Cross-Member: Service and Repair Transmission Support Crossmember 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 (133 lb-in). 3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar. Remove the heat shield bolt from the RH heat shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 5595 - To install, tighten to 18 Nm (159 lb-in). 4. Remove the heat shield bolt from the LH heat shield. - To install, tighten to 18 Nm (159 lb-in). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 5596 Cross-Member: Service and Repair Crossmember - 1B Crossmember - 1B Crossmember 1B Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Vehicle Jacking and Lifting. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Wheel Knuckle Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 5600 Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 and tire. 2. Remove and discard the halfshaft nut. - To install, tighten to 250 Nm (184 lb-ft). 3. Using the Front Wheel Hub Remover, separate the outboard CV joint from the wheel hub. 4. NOTICE: 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 lb-ft). 5. Remove the brake disc. 6. Remove the wheel speed sensor harness bracket bolt from the wheel knuckle. - To install, tighten to 8 Nm (71 lb-in). 7. Disconnect the wheel speed sensor harness pin-type retainers. 8. Disconnect the wheel speed sensor electrical connector. 9. Remove and discard the tie-rod end nut. - To install, tighten the new nut to 103 Nm (76 lb-ft). 10. NOTICE: Do not use a hammer to separate the tie rod from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the tie-rod boot while installing the C-Frame and Screw. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 5601 Using the C-Frame and Screw, separate the tie-rod end from the wheel knuckle. 11. Remove and discard the lower ball joint nut. - To install, tighten the new nut to 150 Nm (111 lb-ft). 12. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the 2-Jaw Puller. Using the 2-Jaw Puller, separate the lower ball joint from the wheel knuckle. 13. Remove and discard the upper ball joint nut. - To install, tighten the new nut to 55 Nm (41 lb-ft). 14. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw. Using the C-Frame and Screw, separate the upper ball joint and remove the wheel knuckle. 15. To install, reverse the removal procedure. - Check and if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Wheel Knuckle Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 5605 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed or incorrect clamp load and damage to components may occur. 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. NOTICE: Do not loosen the halfshaft nut and washer until the wheel and tire are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. NOTE: Do not discard the halfshaft nut at this time. Remove the halfshaft nut. 4. Remove the parking brake shoes. 5. NOTICE: Do not use a hammer to separate the halfshaft from the hub. Damage to the threads and internal Constant Velocity (CV) joint components may result. Using the Front Wheel Hub Remover, 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. For additional information, refer to Wheel Bearing and Wheel Hub See: Wheel Bearing/Service and Repair/Rear Suspension. Installation 1. Position the wheel knuckle and install 3 new wheel knuckle bolts. - Tighten to 275 Nm (203 lb-ft). 2. Install a new lower arm outboard bolt and flagnut. - Tighten the nut to 275 Nm (203 lb-ft). 3. NOTICE: The upper arm outboard bolt must be installed with the bolt head toward the front of the vehicle or wheel damage may occur. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 5606 Install a new upper arm outboard bolt and nut with the bolt head toward the front of the vehicle. - Tighten to 225 Nm (166 lb-ft). 4. Position the toe link and install a new toe link outboard bolt and nut. - Tighten to 325 Nm (240 lb-ft). 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 lb-in). 8. NOTICE: Do not tighten the rear halfshaft nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered to the ground. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. NOTE: Apply the brake to keep the halfshaft from rotating. Position the halfshaft in the hub and use the previously removed halfshaft nut to seat the halfshaft. - Tighten to 275 Nm (203 lb-ft). - Remove and discard the nut. 9. NOTICE: Install and tighten the new halfshaft nut to specification within 5 minutes of starting it on the threads. Always install a new halfshaft nut after loosening or when not tightening within the specified time or damage to the components may occur. Install a new halfshaft nut. - Tighten to 275 Nm (203 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed or incorrect clamp load and component damage may occur. 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 the wheel and tire. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component Information > Service and Repair > Page 5610 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 325 Nm (240 lb-ft). 2. NOTE: Do not tighten the cam adjuster nut at this time. NOTE: The cam adjuster must be installed with the small tooth facing toward the frame bracket. 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 lb-ft). 4. Lower the suspension and remove the jack. 5. Install the wheel and tire. 6. Check and, if necessary, adjust the rear toe. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations Steering Angle Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5615 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 5616 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) Stabilizer Link: Service and Repair Front Suspension - Rear Wheel Drive (RWD) Stabilizer Bar and Link Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as when removed or incorrect clamp load and damage to components may occur. 1. Remove the wheel and tire. 2. Remove and discard the 2 stabilizer bar nuts and grommets. - To install, tighten the new nuts to 35 Nm (26 lb-ft) 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 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 the new bolts to 55 Nm (41 lb-ft) at curb height. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5622 6. NOTICE: The LH and RH side stabilizer bar bushings are different and are not interchangeable. Make sure the bushings are installed on the correct side or damage to the bushings will occur. NOTE: When installing the LH side 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 (V6-4.0L (2009)) 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 Front Suspension - Rear Wheel Drive (RWD) Shock Absorber and Spring Assembly Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as when removed or incorrect clamp load and damage to components may occur. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 5627 2. Remove and discard the 3 shock absorber upper mount nuts. 3. Remove the wheel and tire. 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. 6. Remove and discard the shock absorber lower bolt and flag nut. 7. Remove and discard the upper ball joint nut. 8. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw. Using the C-Frame and Screw, separate the upper ball joint from the wheel knuckle. 9. While lowering the suspension, remove the shock and spring assembly. Installation NOTICE: 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). This will prevent unequal clamp load and bushing damage. NOTE: For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 1. Install the shock absorber and spring assembly. 2. Connect the upper ball joint to the wheel knuckle and install the new upper ball joint nut. - Tighten to 55 Nm (41 lb-ft). 3. NOTE: Do not tighten the bolt at this time. Install the new shock absorber lower bolt and flag nut. 4. Using a suitable jack, 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). 5. Position the stabilizer bar link and install the new nut. - Tighten to 35 Nm (26 lb-ft). 6. Tighten the shock absorber lower bolt to 250 Nm (258 lb-ft). 7. Install the 3 new shock absorber upper mount nuts. - Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 5628 8. Remove the jack. 9. Install the wheel and tire. 10. Check and if necessary, align the front end. Front Suspension Shock Absorber and Spring Assembly Removal and Installation For additional information, refer to Front Suspension - Rear Wheel Drive (RWD). See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Front Suspension - Rear Wheel Drive (RWD) Rear Suspension Shock Absorber and Spring Assembly Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. For additional information, refer to Lower Arm See: Control Arm/Service and Repair/Rear Suspension/Lower Arm. 2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber and spring assembly. - To install, tighten the new nuts to 30 Nm (22 lb-ft). 3. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly See: Suspension Strut / Shock Absorber/Service and Repair/Overhaul/Rear Suspension. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 5629 Suspension Spring ( Coil / Leaf ): Overhaul Front Suspension - Rear Wheel Drive (RWD) Shock Absorber and Spring Assembly Disassembly and Assembly WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 shock absorber and spring assembly. For additional information, refer to Shock Absorber and Spring Assembly. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. NOTICE: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 5630 nut or damage to the shock or bushing may occur. NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. Remove and discard the shock absorber rod nut. - To install, tighten the new nut to 65 Nm (48 lb-ft). 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. NOTICE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening shock absorber rod nut or damage to the bushing may occur. To assemble, reverse the disassembly procedure. Front Suspension Shock Absorber and Spring Assembly Disassembly and Assembly For additional information, refer to Front Suspension - Rear Wheel Drive (RWD). See: Front Suspension - Rear Wheel Drive (RWD) Rear Suspension Shock Absorber and Spring Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 5631 Disassembly and Assembly 1. Remove the shock absorber and spring assembly. For additional information, refer to Shock Absorber and Spring Assembly See: Suspension Strut / Shock Absorber/Service and Repair/Removal and Replacement/Rear Suspension. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. NOTICE: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut or damage to the shock bushing may occur. NOTE: Use the hex-holding feature to prevent the shock absorber rod from turning while removing and installing the nut. Remove and discard the shock absorber rod nut. - To install, tighten the new nut to 65 Nm (48 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Removal and Replacement > Page 5632 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 (V6-4.0L (2009)) 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 Removal and Installation For additional information, refer to Front Suspension - Rear Wheel Drive (RWD). See: Front Suspension - Rear Wheel Drive (RWD) Rear Suspension Shock Absorber and Spring Assembly Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. For additional information, refer to Lower Arm See: Control Arm/Service and Repair/Rear Suspension/Lower Arm. 2. Remove and discard the 3 shock absorber upper mount nuts and remove the shock absorber and spring assembly. - To install, tighten the new nuts to 30 Nm (22 lb-ft). 3. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly See: Overhaul/Rear Suspension. 4. To install, reverse the removal procedure. Front Suspension - Rear Wheel Drive (RWD) Shock Absorber and Spring Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5637 Removal WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as when removed or incorrect clamp load and damage to components may occur. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5638 2. Remove and discard the 3 shock absorber upper mount nuts. 3. Remove the wheel and tire. 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. 6. Remove and discard the shock absorber lower bolt and flag nut. 7. Remove and discard the upper ball joint nut. 8. NOTICE: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle can result. NOTICE: Do not damage the ball joint boot while installing the C-Frame and Screw. Using the C-Frame and Screw, separate the upper ball joint from the wheel knuckle. 9. While lowering the suspension, remove the shock and spring assembly. Installation NOTICE: 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). This will prevent unequal clamp load and bushing damage. NOTE: For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. 1. Install the shock absorber and spring assembly. 2. Connect the upper ball joint to the wheel knuckle and install the new upper ball joint nut. - Tighten to 55 Nm (41 lb-ft). 3. NOTE: Do not tighten the bolt at this time. Install the new shock absorber lower bolt and flag nut. 4. Using a suitable jack, 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). 5. Position the stabilizer bar link and install the new nut. - Tighten to 35 Nm (26 lb-ft). 6. Tighten the shock absorber lower bolt to 250 Nm (258 lb-ft). 7. Install the 3 new shock absorber upper mount nuts. - Tighten to 30 Nm (22 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5639 8. Remove the jack. 9. Install the wheel and tire. 10. Check and if necessary, align the front end. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5640 Suspension Strut / Shock Absorber: Overhaul Front Suspension Shock Absorber and Spring Assembly Disassembly and Assembly For additional information, refer to Front Suspension - Rear Wheel Drive (RWD). See: Front Suspension - Rear Wheel Drive (RWD) Front Suspension - Rear Wheel Drive (RWD) Shock Absorber and Spring Assembly Disassembly and Assembly WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may result in serious personal injury. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts can extend unassisted. Failure to follow this instruction may result in serious personal injury. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 shock absorber and spring assembly. For additional information, refer to 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5641 3. NOTICE: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut or damage to the shock or bushing may occur. NOTE: Use the holding feature to prevent the shock absorber rod from turning while removing and installing the nut. Remove and discard the shock absorber rod nut. - To install, tighten the new nut to 65 Nm (48 lb-ft). 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. NOTICE: Make sure that the upper shock mount stud, shock rod and shock lower bushing are aligned before tightening shock absorber rod nut or damage to the bushing may occur. To assemble, reverse the disassembly procedure. Rear Suspension Shock Absorber and Spring Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5642 Disassembly and Assembly 1. Remove the shock absorber and spring assembly. For additional information, refer to Shock Absorber and Spring Assembly See: Removal and Replacement/Rear Suspension. 2. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. 3. NOTICE: When installing the shock rod nut, make sure the shock rod and bushing are centered in the upper mount before tightening the nut or damage to the shock bushing may occur. NOTE: Use the hex-holding feature to prevent the shock absorber rod from turning while removing and installing the nut. Remove and discard the shock absorber rod nut. - To install, tighten the new nut to 65 Nm (48 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Removal and Replacement > Page 5643 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair Trailing Arm: Service and Repair Trailing Arm Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed or incorrect clamp load and damage to components may occur. 1. Remove the toe link. For additional information, refer to Toe Link See: Rear Knuckle Alignment Link/Service and Repair. 2. Remove the parking brake cable bracket bolt. - To install, tighten to 10 Nm (89 lb-in). 3. Remove and discard the trailing arm bolt. - To install, tighten the new bolt to 300 Nm (222 lb-ft) at curb height. 4. Remove the 3 wheel knuckle bolts and the trailing arm. - Discard the bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair > Page 5647 - To install, tighten the new bolts to 275 Nm (203 lb-ft). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5652 2. Remove and discard the halfshaft nut. - To install, tighten the new nut to 250 Nm (184 lb-ft). 3. Using the Front Wheel Hub Remover, separate the outboard CV joint from the wheel hub. 4. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 bolts and the wheel bearing and hub assembly. - Discard the bolts. - To install, tighten the new bolts to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5653 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. For additional information, refer to Wheel Knuckle See: Rear Knuckle/Service and Repair. 2. Remove the 3 brake disc shield bolts. - To install, tighten to 8 Nm (71 lb-in). 3. Using the Bearing Puller and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5654 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. For additional information, refer to Wheel Knuckle See: Rear Knuckle/Service and Repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft nut....................................................................................................................... ........................................................................250 Nm (184 lb-ft) Rear Drive Halfshaft nut....................................................................................................................... ........................................................................275 Nm (203 lb-ft) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Jacking and Lifting WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury. WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury. WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury. WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury. WARNING: Identify the correct jacking points by locating the triangle stamped into the uni-body sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or falling. Failure to follow this instruction may result in serious personal injury. NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other purpose. NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift without first checking for possible interference. NOTICE: When raising a vehicle on a twin-post hoist, use care when positioning the vehicle so that the hoisting forks do not interfere with the suspension components, mounting brackets or stabilizer mounting brackets, if equipped. In addition, use care in hoist positioning to avoid possible damage to the axle carrier or rear cover. NOTICE: 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. Jacking Points Lifting Points Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 5663 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training 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). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Tire Monitoring System/Testing and Inspection/Programming and Relearning. 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. 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training > Page 5669 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. 8. 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. 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. 10. 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. 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 (V6-4.0L (2009)) 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 Monitoring System (TPMS) Sensor Training > Page 5670 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Tire Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 2. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. 3. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5673 4. Remove the sensor. Assembly 1. NOTICE: Damage to the sensor may 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. 3. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 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 See: Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5674 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor See: Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5675 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory-installed strap in the following 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 in) from the buckle. 2. Using a large screwdriver and a twisting motion, unbuckle the strap. 3. Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. - Discard the strap. 4. 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. NOTICE: Metal scrapers may 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. Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed. 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 degrees from the valve stem. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5676 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. NOTICE: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. 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 in) away from the sensor and tighten the worm gear. - Tighten to 3 Nm (27 lb-in). 6. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire. See: Service and Repair/Overhaul 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. See: Tire Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training 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). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Testing and Inspection/Programming and Relearning. 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. 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 5682 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. 8. 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. 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. 10. 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 5683 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 2. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. 3. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5686 4. Remove the sensor. Assembly 1. NOTICE: Damage to the sensor may 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. 3. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire See: Service and Repair/Overhaul. 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 See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5687 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor See: Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5688 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory-installed strap in the following 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 in) from the buckle. 2. Using a large screwdriver and a twisting motion, unbuckle the strap. 3. Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. - Discard the strap. 4. 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. NOTICE: Metal scrapers may 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. Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed. 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 degrees from the valve stem. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5689 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. NOTICE: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. 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 in) away from the sensor and tighten the worm gear. - Tighten to 3 Nm (27 lb-in). 6. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire. See: Service and Repair/Overhaul 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. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 5698 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > 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 5703 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheels: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 5709 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > 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 5714 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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 and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5719 2. Remove and discard the halfshaft nut. - To install, tighten the new nut to 250 Nm (184 lb-ft). 3. Using the Front Wheel Hub Remover, separate the outboard CV joint from the wheel hub. 4. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft). 5. Remove the brake disc. 6. NOTE: A new wheel bearing and wheel hub comes with the wheel speed sensor installed. Disconnect the wheel speed sensor harness electrical connector and remove and discard the wheel speed sensor harness bracket bolt. - To install, tighten to 8 Nm (71 lb-in). 7. Remove the 3 bolts and the wheel bearing and hub assembly. - Discard the bolts. - To install, tighten the new bolts to 122 Nm (90 lb-ft). 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5720 Wheel Bearing: Service and Repair Rear Suspension Wheel Bearing and Wheel Hub Removal and Installation NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. For additional information, refer to Wheel Knuckle See: Suspension/Rear Knuckle/Service and Repair. 2. Remove the 3 brake disc shield bolts. - To install, tighten to 8 Nm (71 lb-in). 3. Using the Bearing Puller and a suitable press, remove the wheel hub. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5721 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. For additional information, refer to Wheel Knuckle See: Suspension/Rear Knuckle/Service and Repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: Customer Interest Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 5730 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 5736 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Halfshaft nut....................................................................................................................... ........................................................................250 Nm (184 lb-ft) Rear Drive Halfshaft nut....................................................................................................................... ........................................................................275 Nm (203 lb-ft) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications NOTICE: Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the wheel nuts, using the pattern indicated, to..............................................................................................................................135 Nm (100 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) Wheel Fastener: Service and Repair Front Suspension - Rear Wheel Drive (RWD) Wheel Studs Removal 1. Remove the wheel and tire. 2. NOTICE: 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 the new bolts to 165 Nm (122 lb-ft). 3. Remove the brake disc. 4. Using the C-Frame and Screw, remove the wheel stud. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5746 Installation 1. NOTICE: 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. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange. Install approximately 4 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 (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5747 Wheel Fastener: Service and Repair Rear Suspension Wheel Studs Removal NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is 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. NOTICE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same direction as they were in when removed, or incorrect clamp load and component damage may occur. 1. Remove the wheel and tire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5748 2. NOTICE: 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. NOTICE: 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. NOTE: 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 C-Frame and Screw, press the wheel stud until it makes contact with the edge of the wheel knuckle. 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. NOTICE: 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. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub flange. Place approximately 4 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. NOTICE: A plug must be installed in place of the knockout to prevent contamination to the parking brake shoe assemblies. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension - Rear Wheel Drive (RWD) > Page 5749 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 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair Accumulator HVAC: Service and Repair Suction Accumulator Removal and Installation NOTICE: Care must be taken to minimize exposure of the inside of the suction accumulator to outside air. If multiple Air Conditioning (A/C) system components are being removed and installed, the suction accumulator should be installed last. The suction accumulator shipping caps should not be removed until the fittings are ready to be connected. Evacuation of the A/C system must be started as soon as the suction accumulator is installed. Excessive exposure of the inside of the suction accumulator to outside air will result in moisture contamination of the suction accumulator desiccant. NOTE: Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than 1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the suction accumulator should not be replaced. All vehicles 1. Recover the refrigerant. 2. Remove the PCM. 3. Disconnect the A/C cycling switch electrical connector. 4. Remove the suction accumulator bolt. - To install, tighten to 11 Nm (97 lb-in). 5. Remove the PCM bracket bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair > Page 5754 6. Remove the PCM bracket nut and the PCM bracket. 7. Remove the suction accumulator stud. - To install, tighten to 11 Nm (97 lb-in). 4.6L vehicles 8. Remove the suction accumulator-to-compressor line bracket nut at the condenser-to-evaporator line bracket. All vehicles 9. Remove the suction accumulator bracket bolt and suction accumulator. 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > LH Temperature Blend Door Actuator Air Door Actuator / Motor: Locations LH Temperature Blend Door Actuator Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > LH Temperature Blend Door Actuator > Page 5760 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > LH Temperature Blend Door Actuator > Page 5761 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > LH Temperature Blend Door Actuator > Page 5762 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > LH Temperature Blend Door Actuator > Page 5763 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Temperature Blend Door Actuator Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Temperature Blend Door Actuator > Page 5766 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Temperature Blend Door Actuator > Page 5767 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Auxiliary Temperature Blend Door Actuator > Page 5768 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 5771 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 (V6-4.0L (2009)) 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 5772 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. - 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5773 9. Remove the auxiliary mode door actuator. 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5774 Air Door Actuator / Motor: Service and Repair Vacuum Control Motor - Defroster Door Vacuum Control Motor - Defroster Door Removal and Installation 1. Remove the Audio Control Module (ACM). 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 (V6-4.0L (2009)) 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 5775 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. Temperature Blend Door Actuator - RH, EATC Temperature Blend Door Actuator - RH, EATC Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5776 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. Auxiliary Mode Door Actuator Auxiliary Mode Door Actuator Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5777 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. - 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. Vacuum Control Motor - Defroster Door Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5778 Vacuum Control Motor - Defroster Door Removal and Installation 1. Remove the Audio Control Module (ACM). 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. Vacuum Control Motor - Floor Door Vacuum Control Motor - Floor Door Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5779 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5780 10. To install, reverse the removal procedure. Vacuum Control Motor - Panel Door Vacuum Control Motor - Panel Door Removal and Installation 1. Remove the Audio Control Module (ACM). 2. Lower the glove compartment. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5781 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. 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. - 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 5782 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5789 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5790 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 5791 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Climate Control System Component Tests Temperature Sensor - Ambient Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Locations > Page 5796 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 5801 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 5802 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Blower Motor Relay 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Blower Motor Relay 2 > Page 5805 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 5808 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 5809 Blower Motor Relay: Testing and Inspection Blower Motor Relay 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 5810 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 5811 Blower Motor Relay: Testing and Inspection Blower Motor Relay 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 5812 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Front Blower Motor Resistor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Front Blower Motor Resistor > Page 5817 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor > Page 5820 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Resistor - Blower Motor, Front Blower Motor Resistor: Testing and Inspection Resistor - Blower Motor, Front Climate Control System Component Tests Resistor - Blower Motor, Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Resistor - Blower Motor, Front > Page 5823 Blower Motor Resistor: Testing and Inspection Resistor - Blower Motor, Auxiliary Climate Control System Component Tests Resistor - Blower Motor, Auxiliary Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 two 4X4 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Blower Motor Resistor > Page 5826 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5830 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 5831 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5838 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 5839 Cabin Temperature Sensor / Switch: Testing and Inspection Climate Control System Component Tests Temperature Sensor - In-Vehicle Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor > Page 5842 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Compressor Magnetic Clutch Air gap clearance........................................................................... ..........................................................................................0.35-0.65 mm (0.014-0.026 in) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5847 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5851 Compressor Clutch Coil: Service and Repair Clutch and Clutch Field Coil Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5852 Removal All vehicles 1. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - 4.0L SOHC See: Service and Repair or Air Conditioning (A/C) Compressor - 4.6L See: Service and Repair. 2. Remove the A/C clutch disc and hub bolt. 1. Hold the A/C clutch disc and hub with the Compressor Clutch Disc and Hub Holding Fixture. 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. 5. Remove the A/C compressor pulley. 1. Install the Compressor Pulley Remover 2. Remove the A/C compressor pulley. FS18 compressors only 6. NOTICE: Do not use air tools. The Air Conditioning (A/C) clutch field coil can be easily damaged. Remove the A/C clutch field coil. 1. Install the Field Coil Remover. 2. Install the Compressor Pulley Remover. 3. Remove the A/C clutch field coil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5853 FS20 compressors only 7. Remove the A/C clutch field coil snap ring. 8. Remove the A/C clutch field coil electrical connector screw. 9. 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. NOTICE: Do not use air tools. The Air Conditioning (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 Field Coil Replacer on the A/C clutch field coil. 3. Place the Coil Replacer 412-065 on the Field Coil Replacer 412-078. 4. Use the Compressor Pulley Remover 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 electrical connector screw. 6. Install the A/C clutch field coil snap ring. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Diagrams > Page 5854 7. 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. 8. Install the A/C clutch pulley snap ring with the bevel side out. 9. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening. 10. Install the A/C clutch disc and hub assembly. 11. Install the A/C clutch disc and hub bolt. 1. Hold the A/C clutch disc and hub with the Compressor Clutch Disc and Hub Holding Fixture. 2. Install the A/C clutch disc and hub bolt. - Tighten to 14 Nm (124 lb-in). 12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 13. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor - 4.0L SOHC See: Service and Repair or Air Conditioning (A/C) Compressor - 4.6L See: Service and Repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5858 Compressor Clutch Relay: Description and Operation Engine Control Components Air Conditioning (A/C) Clutch Relay (A/CCR) Note: The PCM parameter identifiers (PIDs) wide open throttle air conditioning cutoff (WAC) and wide open throttle air conditioning cutoff fault (WAC_F) 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 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5859 Compressor Clutch Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 5860 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation Air Conditioning Condenser Core 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5864 Condenser HVAC: Service and Repair Condenser Core Removal and Installation 1. Recover the refrigerant. 2. Remove the Air Cleaner (ACL). 3. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. - To install, tighten to 7 Nm (62 lb-in). 4. Disconnect the A/C pressure transducer electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 5865 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 (106 lb-in). 9. Remove the upper radiator air deflector. 10. Remove the 2 condenser core bolts. - To install, tighten to 12 Nm (106 lb-in). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Climate Control Assembly Control Assembly: Diagrams Climate Control Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Climate Control Assembly > Page 5870 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Climate Control Assembly > Page 5871 Control Assembly: Diagrams Auxiliary Climate Control Assembly, Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Climate Control Assembly > Page 5872 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1. Remove the center instrument panel finish panel. 2. Remove the 4 climate control assembly screws. 3. Remove the climate control assembly. 4. Remove the 3 climate control knobs. 5. Depress the tabs and remove the blower motor switch. 6. Depress the tabs and remove the function selector switch. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 5875 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Assembly > Page 5876 Control Assembly: Service and Repair Heating Ventilation Air Conditioning (HVAC) Module Heating Ventilation Air Conditioning (HVAC) Module Removal and Installation NOTE: If installing a new HVAC module, the new module must be configured for the vehicle. 1. Remove the center instrument panel finish panel. 2. Remove the 4 HVAC module screws. 3. Remove the HVAC module. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 5880 Control Module HVAC: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 5881 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation Air Conditioning 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 5885 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. For additional information, refer to Heater Core See: Heater Core/Service and Repair/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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 5894 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 5900 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation Engine Control Components Air Conditioning Evaporator Temperature (ACET) Sensor 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 and improve defrost/demist performance. Note: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Evaporator Core Orifice Expansion Block/Orifice Tube: Description and Operation Evaporator Core Orifice Air Conditioning 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Evaporator Core Orifice > Page 5908 Expansion Block/Orifice Tube: Description and Operation A/C Pressure Transducer Air Conditioning A/C Pressure Transducer The A/C pressure transducer is used by the PCM to monitor the discharge pressure in the high-pressure side of the refrigerant system. When the A/C pressure transducer is reading a discharge pressure above acceptable levels, the PCM will disengage the A/C compressor clutch. The A/C pressure transducer is installed on a Schrader-type valve core fitting on the compressor-to-condenser discharge line. It is not necessary to recover the refrigerant before removing the A/C pressure transducer. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Evaporator Core Orifice Expansion Block/Orifice Tube: Service and Repair Evaporator Core Orifice Evaporator Core Orifice Removal 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. 4. If the evaporator core orifice is intact, engage the Fixed Orifice Remover/Installer. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Evaporator Core Orifice > Page 5911 5. If the evaporator core orifice is broken, screw the end of the Broken Orifice Remover 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 Fixed Orifice Remover/Installer. 2. Install a new O-ring seal and connect the evaporator core orifice access fitting. - To install, tighten to 18 Nm (159 lb-in). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Evaporator Core Orifice > Page 5912 Expansion Block/Orifice Tube: Service and Repair Thermostatic Expansion Valve 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 (TXV). This filter must be inspected before a new TXV is installed. 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 TXV. 4. Remove the 4 clips and the TXV cover. 5. Remove the insulating tape. - Retain the tape for reuse. 6. Remove the temperature sensing bulb clip and detach the temperature sensing bulb from the evaporator outlet line. 7. Disconnect the 2 TXV fittings and remove the TXV. - Discard the O-ring seals. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Evaporator Core Orifice > Page 5913 - 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core Heater Core: Testing and Inspection Heater Core Climate Control System Component Tests Heater Core 1. NOTE: If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: See: Heater Core - Plugged Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5921 Heater Core: Testing and Inspection Heater Core - Plugged Climate Control System Component Tests Heater Core - Plugged 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, using a suitable temperature measuring device, check the heater core inlet and outlet hose to see if they are hot. If the inlet hose is not hot: - the heater control valve may be stuck closed. - the thermostat is not working correctly. If the outlet hose is not hot: - the heater core may have an air pocket. - the heater core may be restricted or plugged. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5922 Heater Core: Testing and Inspection Heater Core - Pressure Test Climate Control System Component Tests Heater Core - Pressure Test Use the Pressure Test Kit to perform the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and Adapter BT-7422-A from the Pressure Test Kit in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. See: Heater Core - Bench Test Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Testing and Inspection > Heater Core > Page 5923 Heater Core: Testing and Inspection Heater Core - Bench Test Climate Control System Component Tests Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester from the Pressure Test Kit to the adapter. 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. For additional information, refer to Heater Core And Evaporator Core Housing See: Housing Assembly HVAC/Service and Repair/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. 8. Remove the 3 heater tube cover screws. 9. Remove the heater tube cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 5926 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 5927 Heater Core: Service and Repair Auxiliary Heater Core Auxiliary Heater Core Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 5928 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. 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 heater core and evaporator core housing bolts and auxiliary heater core and evaporator core 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core > Page 5929 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 (V6-4.0L (2009)) 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 Air Conditioning A/C Pressure Relief Valve NOTE: If the A/C compressor is operating within limits and the A/C pressure relief valve is venting, or if the A/C pressure relief valve is leaking around the threads, replace the A/C pressure relief valve and O-ring. If the A/C pressure relief valve still vents after it is replaced, diagnose the refrigerant system for a restriction. 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. The A/C pressure relief valve is a separate component and can be replaced separately from the A/C compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief valve. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > Page 5933 High Pressure Safety Valve HVAC: Service and Repair Air Conditioning (A/C) Pressure Relief Valve Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the A/C compressor pressure relief valve and O-ring seal. - To install, tighten to 10 Nm (89 lb-in). 4. NOTE: A new O-ring seal will already be installed on the new A/C pressure relief valve service part. To install, reverse the removal procedure. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 5. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 - 4.0L SOHC Removal and Installation 1. Recover the refrigerant. 2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 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 compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. - Install a new gasket seal and O-ring seals. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5938 - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5939 Hose/Line HVAC: Service and Repair Condenser To Evaporator Line Condenser to Evaporator Line Removal and Installation All vehicles 1. Remove the Air Cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5940 - Discard the O-ring seal. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5941 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Front Auxiliary Evaporator Outlet and Inlet Line - Front Removal and Installation 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5942 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5943 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line - Rear Auxiliary Evaporator Outlet and Inlet Line - Rear Removal and Installation 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5944 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5945 Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line Compressor to Condenser Discharge Line - 4.0L SOHC Removal and Installation 1. Recover the refrigerant. 2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. - To install, tighten to 7 Nm (62 lb-in). 3. Remove the compressor discharge fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 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 compressor-to-condenser discharge line. 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5946 - Install a new gasket seal and O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 8. Evacuate, leak test and charge the refrigerant system. Condenser To Evaporator Line Condenser to Evaporator Line Removal and Installation All vehicles 1. Remove the Air Cleaner (ACL) and ACL outlet tube. 2. Recover the refrigerant. 3. Remove the 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). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5947 All vehicles 6. Disconnect the evaporator core orifice access fitting. - Discard the O-ring seal. 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. Auxiliary Evaporator Outlet and Inlet Line - Front Auxiliary Evaporator Outlet and Inlet Line - Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5948 Removal and Installation 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). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5949 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. Auxiliary Evaporator Outlet and Inlet Line - Rear Auxiliary Evaporator Outlet and Inlet Line - Rear Removal and Installation Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5950 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. Suction Accumulator To Compressor Line Suction Accumulator to Compressor Line - 4.0L SOHC Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5951 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the compressor suction fitting nut and disconnect the fitting. - Discard the O-ring seal and gasket seal. - To install, tighten to 15 Nm (133 lb-in). 4. Release the brake booster vacuum hose clamp and disconnect the hose. 5. Remove the suction accumulator-to-compressor line bracket bolt at the dash panel. - To install, tighten to 11 Nm (97 lb-in). 6. Remove the suction accumulator outlet fitting nut. - To install, tighten to 8 Nm (71 lb-in). 7. Disconnect the auxiliary evaporator outlet line fitting (if equipped). - Discard the O-ring seals. 8. Remove the suction accumulator-to-compressor line. - Discard the O-ring seal. 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. Suction Accumulator To Evaporator Line Suction Accumulator To Evaporator Line Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5952 Removal and Installation All vehicles 1. Remove the suction accumulator. For additional information, refer to Suction Accumulator See: Accumulator HVAC/Service and Repair. 2. 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). 3. Remove the ground strap bolt at the dash panel. 4. Disconnect the evaporator outlet fitting. - Discard the O-ring seals. Vehicles with 4.0L engine 5. Disconnect the Evaporative Emission (EVAP) return line fitting at the intake manifold. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5953 6. Remove the fuel line bracket bolt at the rear of the RH valve cover. 7. Remove the wire harness bolt at the rear of the RH cylinder head. All vehicles 8. Remove the suction accumulator-to-evaporator line. 9. To install, reverse the removal procedure. - Install new O-ring seals. - Lubricate the refrigerant system with the correct amount of clean PAG oil. Auxiliary Heater Outlet and Inlet Line - Front Auxiliary Heater Outlet and Inlet Line - Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5954 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. Auxiliary Heater Outlet and Inlet Line - Rear Auxiliary Heater Outlet and Inlet Line - Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5955 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. - 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor To Condenser Discharge Line > Page 5956 12. To install, reverse the removal procedure. 13. Fill the engine cooling system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. NOTE: Lubricate the coolant hoses with plain water only if needed. 1. Recover the refrigerant. 2. Drain the engine coolant. 3. Remove the instrument panel. 4. Detach the wiring harness bracket and position the harness aside. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5961 5. Remove the heater tube bracket nut. 6. Remove the dash panel A/C line bracket nut. - To install, tighten to 11 Nm (97 lb-in). 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5962 17. Evacuate, leak test and charge the refrigerant system. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5963 Housing Assembly HVAC: Service and Repair Plenum Chamber Plenum Chamber Removal and Installation 1. Remove the instrument panel. 2. Remove the Audio Control Module (ACM). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5964 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Heater Core And Evaporator Core Housing > Page 5965 Removal and Installation NOTE: 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. - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...........................................................................................................................(0.77 kg) (27 oz) (1.7 lb) (vehicles without auxiliary systems) Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...................................................................................................................(1.25 kg) (44 oz) (2.75 lb) (vehicles with auxiliary climate control) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5970 Refrigerant: Fluid Type Specifications Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...........................................................................................................................(0.77 kg) (27 oz) (1.7 lb) (vehicles without auxiliary systems) Item..............................................................................................................................R-134a Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification........................................... ......................................................................................................................................................WS H-M17B19-A Fill Capacity...................................................................................................................(1.25 kg) (44 oz) (2.75 lb) (vehicles with auxiliary climate control) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5971 Refrigerant: Testing and Inspection Refrigerant Identification Testing Refrigerant Identification 1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken directly from the refrigeration system or storage containers prior to recovering or charging the refrigerant system. Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the sample for testing. 2. The Refrigerant Blend Identifier with Printer will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital display. - If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will be displayed on the digital display. - If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light, "Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will also be displayed on the digital display. 3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or greater. The Refrigerant Blend Identifier with Printer eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant, although air can affect A/C system performance. When the Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the scan tool will prompt the user if an air purge is desired. 4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated. Contaminated Refrigerant Handling NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered refrigerant supply and may damage the recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system flushing procedure. 1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. - If this equipment is not available, contact an A/C service facility in the area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the A/C system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant: Service and Repair Air Conditioning (A/C) System Recovery, Evacuation and Charging Air Conditioning (A/C) System Recovery, Evacuation and Charging Refrigerant System Recovery NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5974 facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and instructions. NOTE: Ford Motor Company recommends the use of R-134a refrigerant management equipment that meets the requirements of the SAE J2788 standard. NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery. If a R-134a Refrigerant Management Machine is not available, refrigerant system recovery may be accomplished using a separate recovery station. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Prior to recovering, the purity of the refrigerant must be verified. For additional information, refer to Refrigerant Identification Testing See: Testing and Inspection/Component Tests and General Diagnostics/Refrigerant Identification Testing. 2. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. Note the amount of oil removed during the refrigerant recovery (if any). Add that same amount back into the system once repairs are complete. 4. Once the R-134a Refrigerant Management Machine has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Refrigerant System Evacuation Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out recovery, evacuation and charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect a R-134a Refrigerant Management Machine to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes. 3. Turn OFF the Vacuum Pump. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using a R-134a Manifold Gauge Set and Vacuum Pump NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out evacuation of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system evacuation may be accomplished using a separate Vacuum Pump and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a Manifold Gauge Set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the R-134a Manifold Gauge Set to the suction port on the Vacuum Pump. 3. Open all valves on the R-134a Manifold Gauge Set and both service gauge port valves. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5975 4. Turn on the Vacuum Pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the Vacuum Pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the R-134a Manifold Gauge Set (not the service gauge port valves) and turn OFF the Vacuum Pump. 6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using a R-134a Refrigerant Management Machine NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Service and Repair/Refrigerant Oil Adding. 2. Connect a R-134a Refrigerant Management Machine to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging Using a R-134a Manifold Gauge Set and Automatic Refrigerant Charging Meter NOTE: Ford Motor Company recommends use of a R-134a Refrigerant Management Machine to carry out charging of the refrigerant system. If a R-134a Refrigerant Management Machine is not available, refrigerant system charging may be accomplished using a separate Automatic Refrigerant Charging Meter and R-134a Manifold Gauge Set. NOTE: Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Service and Repair/Refrigerant Oil Adding. 2. Assemble the R-134a Manifold Gauge Set, Automatic Refrigerant Charging Meter and R-134a supply tank following the Automatic Refrigerant Charging Meter operating instructions. 3. Charge the refrigerant system following the Automatic Refrigerant Charging Meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select MAX A/C operation and allow the refrigerant charge to complete. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5976 Refrigerant: Service and Repair Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation WARNING: Use extreme care and observe all safety and service precautions related to the use of refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow these instructions may result in serious personal injury. NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer's procedures and instructions. NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any foreign material. These components are typically discarded after A/C system contamination. Hoses without mufflers can normally be reused unless they are clogged with foreign material. The filter is intended for use on one vehicle only. 1. Orient the filter inlet toward the A/C condenser core. 2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for low-pressure flushing and are not designed for use with a charged refrigerant system. Do not make the condenser fitting connections using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur. NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the end of this procedure. Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2 halves of the fitting. - Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. - Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush and Purge Fitting Kit. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Air Conditioning (A/C) System Recovery, Evacuation and Charging > Page 5977 3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding See: Service and Repair/Refrigerant Oil Adding. 4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C operation and set the blower motor speed to maximum. Start the engine and let it idle briefly. Make sure the A/C system is operating correctly. 7. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C system operating. 8. Stop the engine. 9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the condenser to evaporator tube. 11. Discard the pancake filter. It can be used one time only. 12. Reconnect the condenser outlet fitting. 13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair Refrigerant Oil: Service and Repair Refrigerant Oil Adding Refrigerant Oil Adding NOTE: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed, some of the PAG oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. 1. Refer to the chart below for refrigerant oil adding amounts and methods of installation. a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the total system PAG oil capacity must be added. b The amount specified may be used for one or multiple O-ring leak repairs. Do not multiply the PAG oil amount by the number of O-ring leaks being repaired. Adding Refrigerant Oil After A/C Compressor Replacement Service A/C compressors shipped without clutch and pulley 1. Rotate the A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 oz), pour the same amount plus 30 ml (1 oz) of clean PAG Refrigerant Compressor Oil (R-134a Systems) (YN-12-D) WSH M1C231-B or equivalent into the new A/C compressor. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Page 5981 - If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. - If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 oz), pour 85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new A/C compressor. Service A/C compressors shipped with clutch and pulley 2. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring device. - If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml (4 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 118 ml (4 oz), remove 59 ml (2 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is 148 ml (5 oz), remove 29 ml (1 oz) from the new A/C compressor. - If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0 ml (0 oz) from the new A/C compressor. Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or TXV have also been installed due to system contamination, refer to the appropriate heading. 1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and 60 ml (2 fl oz). Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system contamination and the A/C system has been flushed. NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port. 2. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during system charging. For the total PAG oil capacity specification, refer to the Specifications table. Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the PAG oil. 1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. 2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On Injector Kit-Set to match the amount of refrigerant compressor oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. 4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Service and Repair > Page 5982 5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set. 6. Open all valves and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5986 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 5989 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch Engine Control Components Air Conditioning (A/C) Cycling Switch The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to the Climate Control System Air Conditioning System Overview. Also, refer to the applicable Wiring Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to wide open throttle air conditioning cutoff (WAC). Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 5992 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch Engine Control Components Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled for electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. For additional information, refer to the Climate Control System, Air Conditioning System Overview or the Wiring Diagrams. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 5993 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP) Transducer Sensor Engine Control Components Air Conditioning Pressure (ACP) Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. A/C Pressure Transducer Sensor Output Voltage Vs Pressure Chart Typical ACP Transducer Sensor Typical ACP Transducer Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 5999 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Auxiliary Blower Motor Relay > Page 6000 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Blower Motor Relay 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Blower Motor Relay 2 > Page 6003 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6006 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6007 Blower Motor Relay: Testing and Inspection Blower Motor Relay 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6008 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6009 Blower Motor Relay: Testing and Inspection Blower Motor Relay 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Auxiliary Blower Motor Relay > Page 6010 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6014 Compressor Clutch Relay: Description and Operation Engine Control Components Air Conditioning (A/C) Clutch Relay (A/CCR) Note: The PCM parameter identifiers (PIDs) wide open throttle air conditioning cutoff (WAC) and wide open throttle air conditioning cutoff fault (WAC_F) 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 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6015 Compressor Clutch Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 6016 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 6020 Control Module HVAC: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 6021 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor / Switch HVAC: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6026 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6027 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6028 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Climate Control System Component Tests Temperature Sensor - Ambient Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6032 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 6033 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6037 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Locations > Page 6038 Cabin Temperature Sensor / Switch: Testing and Inspection Climate Control System Component Tests Temperature Sensor - In-Vehicle Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor Cabin Temperature Sensor / Switch: Service and Repair Ambient Air Temperature Sensor 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Ambient Air Temperature Sensor > Page 6041 Cabin Temperature Sensor / Switch: Service and Repair In-Vehicle Temperature Sensor 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 (V6-4.0L (2009)) 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 Engine Control Components Air Conditioning Evaporator Temperature (ACET) Sensor 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 and improve defrost/demist performance. Note: These values can vary 15% due to sensor and VREF variations. Voltage values were calculated for VREF equals 5.0 volts. A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 6048 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > A/C Cycling Switch > Page 6051 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) Cycling Switch Engine Control Components Air Conditioning (A/C) Cycling Switch The A/C cycling switch may be wired to either the ACCS or ACPSW PCM input. When the A/C cycling switch opens, the PCM turns off the A/C clutch. For information on the specific function of the A/C cycling switch, refer to the Climate Control System Air Conditioning System Overview. Also, refer to the applicable Wiring Diagrams for vehicle specific wiring. If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate. For additional information, refer to wide open throttle air conditioning cutoff (WAC). Some applications do not have a dedicated (separate) input to the PCM indicating that A/C is requested. This information is received by the PCM through the communication link. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 6054 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning (A/C) High Pressure Switch Engine Control Components Air Conditioning (A/C) High Pressure Switch The A/C high pressure switch is used for additional A/C system pressure control. The A/C high pressure switch is either dual function for multiple speed, relay controlled for electric fan applications, or single function for all others. For refrigerant containment control, the normally closed high pressure contacts open at a predetermined A/C pressure. This results in the A/C turning off, preventing the A/C pressure from rising to a level that would open the A/C high pressure relief valve. For fan control, the normally open medium pressure contacts close at a predetermined A/C pressure. This grounds the ACPSW circuit input to the PCM. The PCM then turns on the high speed fan to help reduce the pressure. For additional information, refer to the Climate Control System, Air Conditioning System Overview or the Wiring Diagrams. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Air Conditioning (A/C) Cycling Switch > Page 6055 Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Pressure (ACP) Transducer Sensor Engine Control Components Air Conditioning Pressure (ACP) Transducer Sensor The ACP transducer sensor is located in the high pressure (discharge) side of the A/C system. The ACP transducer sensor provides a voltage signal to the PCM that is proportional to the A/C pressure. The PCM uses this information for A/C clutch control, fan control and idle speed control. A/C Pressure Transducer Sensor Output Voltage Vs Pressure Chart Typical ACP Transducer Sensor Typical ACP Transducer Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Page 6059 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Air Conditioning 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 A/C 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Page 6066 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations > Page 6073 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Inspection and Repair After a Supplemental Restraint System (SRS) Deployment WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a Supplemental Restraint System (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate diagnostic/repair information procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the Restraints Control Module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle 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 be cleared from all required modules after repairs are carried out. Vehicles with Occupant Classification Sensor (OCS) system 2. NOTE: After installation of new Occupant Classification Sensor (OCS) system components, carry out the Occupant Classification Sensor (OCS) System Reset procedure as instructed in the diagnostic/repair information. Refer to the appropriate diagnostic/repair information for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the Occupant Classification System Module (OCSM) has DTC B1231/B1193:00 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: For rail-type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. Do not install a new OCSM unless DTC B1231 cannot be cleared. - For weight sensor bolt-type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231/B1193:00 cannot be cleared. - NOTE: Most bladder-type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder-type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Seat Belt Systems. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6079 - Instrument panel and mounting points - Seats and seat mounting points - Safety belts, safety belt buckles and safety belt retractors. For additional information, refer to Seat Belt Systems. - 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 (V6-4.0L (2009)) 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 6080 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision Safety Belt Procedure After a Collision WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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). For additional information, refer to the appropriate procedure. Carry out all applicable Functional Tests for the component(s). For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. 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 this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagram. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition to OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6086 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6087 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the cover and RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6088 7. Remove the 2 driver air bag module bolts (1 shown). 8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Open and lower the glove compartment door. 10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield. 11. NOTE: The canister vent and adaptive tether do not require deactivation. Disconnect the LH side passenger air bag module electrical connector. 12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Disengage the passenger seat side air bag module electrical connector locking clip, release the tab and disconnect the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 13. Release and position aside the passenger side C-pillar trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6089 14. Disconnect the passenger side safety canopy module electrical connector. 15. Release and position aside the driver side C-pillar trim panel. 16. Disconnect the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 17. Remove the driver and passenger side upper C-pillar trim panels. 18. Disconnect the passenger side safety canopy module electrical connector. 19. Disconnect the driver side safety canopy module electrical connector. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6090 20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module electrical connector locking clip, release the tab and disconnect the driver seat side air bag module electrical connector. 21. Install the RCM fuse 17 (10A) to the SJB. 22. 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. 3. Connect the driver seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles 4. Connect the driver side safety canopy module electrical connector. 5. Connect the passenger side safety canopy module electrical connector. 6. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 7. Connect the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6091 8. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 11. Connect the passenger seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Attach the passenger seat side air bag module electrical connector to the seat track bracket. 12. Connect the LH side passenger air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6092 13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer. 14. NOTICE: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. 15. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 16. Turn the ignition switch from OFF to ON. 17. Install RCM fuse 17 (10A) to the SJB and install the cover. 18. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 19. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 6097 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Side Air Bag Module, Left > Page 6098 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6101 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6102 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6103 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6104 Air Bag: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6105 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6106 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6107 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6108 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6109 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Air Bag Unit 1 > Page 6110 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger Air Bag: Service and Repair Air Bag Trim Cover - Passenger Air Bag Trim Cover - Passenger Removal WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Do not use any sharp tools to separate the passenger air bag module trim cover from the passenger air bag module canister. Sharp tools may damage the passenger air bag module. Failure to follow this instruction may result in the passenger air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Do not unpack or unroll the passenger air bag module soft pack. If the soft pack becomes unpacked or unrolled, install a new passenger air bag module assembly. Failure to follow these instructions may result in the passenger air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Do not manipulate or compromise the passenger air bag module hooks during the removal or installation procedure. Failure to follow this instruction may result in the passenger air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. 1. Remove the passenger air bag module. For additional information, refer to Passenger Air Bag Module See: Passenger Air Bag Module. 2. Place a mark on top of the passenger air bag module canister for correct installation. 3. Carefully lift the passenger air bag module cover from the bottom of the air bag module canister, separating the windows from the canister hooks. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6113 4. NOTE: Place an X mark on the old air bag cover to avoid reinstalling. Remove the passenger air bag cover from the canister, separating the top windows from the canister hooks. Installation 1. Place the passenger air bag cover on a clean work surface once it is removed from the shipping package. 2. WARNING: Carefully inspect the passenger air bag trim cover, canister and soft pack before assembly. If any foreign objects are found, remove them before attaching the passenger air bag trim cover to the canister. If the canister or soft pack is damaged, install a new passenger air bag module assembly. Failure to follow this instruction may result in the passenger air bag module deploying incorrectly, which increases the risk of serious personal injury or death in a crash. Match the number of cover windows to the number of canister hooks before attaching the passenger air bag cover to the canister. 3. Match the top of the passenger air bag cover with the canister mark from the removal procedure. 4. Position the canister onto the passenger air bag cover and engage the bottom hooks into the air bag cover windows. 5. Push the top of the passenger air bag cover to engage the top canister hooks. 6. Inspect the passenger air bag cover windows-to-canister hooks to verify that every window has a hook installed and the sides are not tucked or folded against the air bag canister. 7. Install the passenger air bag module. For additional information, refer to Passenger Air Bag Module See: Passenger Air Bag Module. 8. NOTE: The video procedure utilizes a Fusion/Milan passenger air bag module assembly. It also applies to vehicles with similar passenger air bag module designs. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6114 Air Bag: Service and Repair Driver Air Bag Module Driver Air Bag Module Removal WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the 2 driver air bag module bolts. - To install, tighten to 7 Nm (62 lb-in). 3. NOTE: Match 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 driver air bag module. 4. To install, reverse the removal procedure. 5. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6115 Air Bag: Service and Repair Passenger Air Bag Module Passenger Air Bag Module Removal and Installation WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTICE: Do not install a new passenger air bag module assembly due to a damaged or discolored passenger air bag cover. The passenger air bag cover can be serviced separately from the passenger air bag module assembly. For additional information, refer to Air Bag Trim Cover Passenger See: Air Bag Trim Cover - Passenger. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Open and lower the glove compartment door. 3. Release the wiring retainer, 4 bolts and passenger air bag module heat shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6116 4. Disconnect the 2 passenger air bag module electrical connectors. 5. Remove the 4 passenger air bag module nuts. - To install, tighten to 9 Nm (80 lb-in). 6. NOTICE: Do not handle the passenger air bag module by grabbing the edges of the passenger air bag cover. Damage to the air bag module may occur. Push up to release the passenger air bag cover clips from the instrument panel and remove the passenger air bag module. 7. NOTE: During passenger air bag module installation, make sure all of the air bag trim cover clips are fully seated into the instrument panel. To install, reverse the removal procedure. 8. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6117 Air Bag: Service and Repair Safety Canopy Module Safety Canopy Module - Explorer Sport Trac NOTE: RH shown, LH similar. Removal WARNING: Anytime the Safety Canopy(R) or side air curtain module has deployed, a new headliner and new A-, B-, C- and D-pillar upper trim panels and attaching hardware must be installed. Remove any other damaged components and hardware and install new components and hardware as needed. Failure to follow these instructions may result in the Safety Canopy(R) or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Always carry or place a live Safety Canopy(R), or side air curtain module, with the module and tear seam pointed away from your body. Failure to follow this instruction may result in serious personal injury or death in the event of an accidental deployment. WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy(R) or side air curtain module. Failure to follow this instruction may result in the Safety Canopy(R) or side air curtain module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6118 may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the headliner. Vehicles with moon roof 3. NOTE: Note the position of the 2 rear moon roof drain hose routing clips for installation. Disconnect the rear moon roof drain tube and detach the 2 rear moon roof 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6119 Installation WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy(R) module, side air curtain module or interior trim panel. This will prevent the Safety Canopy(R) or side air curtain module from deploying correctly. Failure to follow this instruction may increase the risk of serious personal injury or death in a crash. WARNING: When installing a new headliner on a vehicle equipped with Safety Canopy(R) or side air curtain modules, make sure the headliner has the word AIRBAG on the headliner where it meets each B-pillar trim panel. Otherwise, you have the wrong headliner. Failure to follow this instruction may result in the Safety Canopy(R) or side air curtain module not deploying or deploying incorrectly, increasing the risk of personal injury or death in a crash. WARNING: Always use new torque-prevailing type J-nuts when installing the Safety Canopy(R) in the vehicle. Use of these J-nuts is mandatory to reduce the risk of loss of fastener effectiveness. Failure to follow this instruction may result in the Safety Canopy(R) module deploying incorrectly and increases the risk of serious personal injury or death in a crash. WARNING: Before installing a Safety Canopy(R) or side air curtain module, inspect the roofline for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. Install new fasteners if damaged and remove foreign material. Failure to follow these instructions may result in the Safety Canopy(R) or side air curtain deploying incorrectly, which increases the risk of serious personal injury or death in a crash. 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. 4. Install the safety canopy module B-pillar bracket hook in the sheet metal. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6120 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 (106 lb-in). 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 moon roof 12. NOTE: Make sure to route the moon roof drain hose as noted during removal. Connect the rear moon roof drain tube and attach the 2 rear moon roof drain hose clips. All vehicles 13. Install the headliner. 14. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6121 Air Bag: Service and Repair Side Air Bag Module Side Air Bag Module NOTE: Driver seat shown, passenger similar. Removal WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. NOTICE: 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: When replacing the side air bag after deployment, refer to Seats for additional information concerning the installation of a new side air bag module. The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the front seat. 3. Remove the seat backrest. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6122 4. 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. 5. Release the seat back lower outer trim cover J-clip. 6. Release the seat back lower inner trim cover J-clip. 7. WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. NOTICE: Use care when separating the seat backrest trim cover from the hook-and-loop strips, or the hook-and-loop strip can be torn from the seat backrest foam pad. 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. 8. Remove the first row of hog rings. 9. Detach the hook-and-loop strips and invert the seat backrest trim cover up enough to expose the side air bag. 10. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6123 11. Position out the seat backrest foam pad. 12. Remove the 2 bolts and the side air bag module. Installation WARNING: Inspect the seat side air bag module and mounting surfaces for any damage or foreign material before installing the seat side air bag module. If any damage is found, install new components. If any foreign material is found, remove it. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. WARNING: Before installing the seat side air bag module/deployment chute assembly: - Inspect the side air bag module and mounting surfaces for any damage or foreign material. - Remove any foreign material from the mounting surfaces of the deployment chute, the seat backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad. - Install new parts if damaged. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. NOTICE: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the backrest frame. Damage to the wire harness may occur. All seats 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Trim Cover - Passenger > Page 6124 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. 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. Driver Seat 11. Install the driver seat and repower the SRS. Passenger seat 12. Install the passenger seat and repower the SRS. Do not prove out the SRS at this time. 13. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6128 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 6129 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 6132 Air Bag Control Module: Diagrams Restraints Control Module (RCM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 6133 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 6134 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 6135 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) Removal WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). Failure to follow these instructions may result in component damage and/or system failure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: When installing a new Restraints Control Module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. NOTE: The air bag warning indicator illuminates when the correct RCM fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. If installing a new RCM, carry out the steps necessary to prepare for Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 6136 3. Remove the front floor console. 4. Disconnect the large 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 1. Install the RCM. 2. Install the 3 RCM nuts. - Tighten to 12 Nm (106 lb-in). 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. NOTICE: Putting the large electrical connector into the Restraints Control Module (RCM) on an angle may cause bad electrical connections and damage components. Position the large electrical connector into the RCM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Page 6137 6. Connect the large RCM connector. - NOTICE: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the Restraints Control Module (RCM), before using the lever to fully seat the connector. Damage to the connector or component may occur. With the large 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 front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 9. When installing a new RCM, carry out the steps necessary to complete Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 10. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 6141 Air Bag Deactivation Indicator: Service and Repair Passenger Air Bag Deactivation (PAD) Indicator Removal and Installation 1. NOTE: Ignition must be OFF if disconnecting the Passenger Air Bag Deactivation (PAD) indicator electrical connector. Otherwise, a DTC will be set in the Restraints Control Module (RCM) memory and must be cleared before releasing the vehicle. Turn the ignition OFF and wait at least one minute. 2. Remove the floor console. 3. Gently pull outward to release the clips on the instrument panel center finish panel. 4. Disconnect the PAD indicator electrical connector. 5. Remove the 2 screws and PAD indicator. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6145 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6146 Clockspring Assembly / Spiral Cable: Service and Repair Clockspring Removal NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the driver air bag module. For additional information, refer to Driver Air Bag Module See: Air Bag/Service and Repair/Driver Air Bag Module. 2. Remove the steering wheel. 3. Remove the 2 screws and instrument panel lower steering column opening cover. 4. Remove the 3 screws and lower steering column shroud. 5. Remove the upper steering column shroud. 6. Disconnect the clockspring electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6147 7. Remove the 2 screws and position aside the steering wheel rotation sensor. 8. Remove the 2 clockspring screws and remove the clockspring. Installation 1. NOTICE: If installing a new clockspring, do not remove the clockspring anti-rotation key until the steering wheel is installed. If the anti-rotation key has been removed before installing the steering wheel, the clockspring must be centered. Failure to follow this instruction may result in component damage and/or system failure. Install the clockspring and 2 screws. 2. Install the steering wheel rotation sensor and 2 screws. 3. Connect the clockspring electrical connector. 4. Install the upper steering column shroud. 5. Install the lower steering column shroud and 3 screws. 6. Install the instrument panel lower steering column opening cover and 2 screws. 7. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in doubt, repeat the centralizing procedure. Failure to follow these instructions may increase the risk of serious personal injury or death in a crash. NOTICE: To prevent component damage and/or system failure, when reusing a clockspring it must be centered. NOTICE: Do not over-rotate the clockspring inner rotor. The internal ribbon wire is connected to the clockspring rotor. The internal ribbon wire acts as a stop and can be broken from its internal connection. Failure to follow this instruction may result in component damage and/or system failure. If a new clockspring was installed and the anti-rotation key has not been removed, GO to Step 9. If a new clockspring was installed and the anti-rotation key has been removed before the steering wheel is installed or the same clockspring is being installed, rotate the clockspring inner rotor counterclockwise and carefully feel for the ribbon wire to run out of length with slight resistance. Stop rotating the clockspring inner rotor at this point. 8. Starting with the clockspring inner rotor, wiring and connector in the 12 o'clock position, rotate the inner rotor clockwise through 2 revolutions to center the clockspring. The clockspring inner rotor, wiring and connector must be in the 12 o'clock position. 9. NOTICE: To prevent damage to the clockspring, make sure the road wheels are in the straight-ahead position. NOTE: The clockspring inner rotor, wiring and connector must be in the 12 o'clock position to install the steering wheel. Install the steering wheel. 10. If a new clockspring was installed, remove the anti-rotation key. 11. Install the driver air bag module. For additional information, refer to Driver Air Bag Module See: Air Bag/Service and Repair/Driver Air Bag Module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor Impact Sensor: Locations RH Front Impact Severity Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6152 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6153 Impact Sensor: Locations LH Front Impact Severity Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6154 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6155 Impact Sensor: Locations Side Impact Sensor, Second Row Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6156 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6157 Impact Sensor: Locations Side Impact Sensor, Second Row Passenger Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6158 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6159 Impact Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6160 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6161 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6162 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6163 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6164 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6165 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6166 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6167 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6168 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6171 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6172 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6173 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6174 Impact Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6175 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6176 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the 4 pin-type retainers and lower radiator air deflector. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the bolt and front impact severity sensor. To install, tighten to 12 Nm (106 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6179 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6180 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar Side Impact Sensor - C-Pillar, Explorer Sport Trac NOTE: RH shown, LH similar. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: The RH and LH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6181 6. NOTE: Note the position of the sensor and bracket locating tab for installation. NOTE: 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 (106 lb-in). 7. Disconnect the electrical connector and remove the side impact sensor. 8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 9. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6182 Impact Sensor: Service and Repair Side Impact Sensor - Front Door Side Impact Sensor - Front Door NOTE: LH side shown, RH similar. Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the weathershield on the door to access the side impact sensor (pressure sensor). 4. Disconnect the electrical connector. 5. Remove the bolt and side impact sensor. - To install, tighten to 9 Nm (80 lb-in). 6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 7. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 6186 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 6187 Seat Occupant Classification Module - Air Bag: Service and Repair Occupant Classification System Module (OCSM) NOTE: Power seat shown, manual seat similar. Removal NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Disconnect the Occupant Classification System Module (OCSM) electrical connector underneath the front of the passenger seat. 3. NOTE: Note the position of the locator tab on the OCSM for installation. Remove the 2 screws and the OCSM. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 6. Carry out the appropriate procedure after installation of an Occupant Classification Sensor (OCS) system component. - If installing the original OCS system component, carry out the OCS System Zero Seat Weight Test and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Testing and Inspection/Component Tests and General Diagnostics. - If installing a new OCS system component, carry out the OCS Reset and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Service and Repair/Occupant Classification Sensor (OCS) System Reset. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > OCS Rail 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > OCS Rail 1 > Page 6192 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6193 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor NOTE: Outboard Occupant Classification Sensor (OCS) rail shown, inboard similar. Removal WARNING: The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat or dropped after it is installed to a front passenger seat track assembly. Use care when handling an OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. WARNING: Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat track may be removed and installed. Failure to follow these instructions may result in incorrect operation of the OCS system and increase the risk of serious personal injury or death in a crash. WARNING: Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. WARNING: Use care when handling the front passenger seat and track assembly. Dropping the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle may result in damaged seat components. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6194 crash. NOTICE: Prevent oil and/or grease from getting on the Occupant Classification Sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the front passenger seat. 2. NOTICE: Before releasing the Occupant Classification Sensor (OCS) rail electrical connector, push only on the tip of the connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail electrical connector or damage to the electrical connector may occur. NOTE: Note the Occupant Classification Sensor (OCS) rail position, electrical wiring routing, wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers and 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 stop position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the OCS rail. 6. Move the seat to the rearward stop position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6195 7. NOTE: Note the locator tab position where the OCS rail goes through the rail shield and into the rear seat track mounting point for installation. Remove the 2 front bolts and OCS rail and shield. Installation NOTE: If installing a new seat track, position the seat track where the seat will be in the full rearward position before installing the OCS rails. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. 1. WARNING: To prevent foreign material and contaminants from entering the occupant classification sensor (OCS) rail, make sure the OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: Prevent oil and/or grease from getting on the Occupant Classification Sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Install the shield on the OCS rail, and install the OCS rail and shield on the seat track with the locator tab aligned correctly as shown. 2. Hold the OCS rail and shield firmly in position and install the front mounting position rear bolt. - Tighten to 25 Nm (18 lb-ft). 3. Hold the OCS rail and shield firmly in position and install the front mounting position front bolt. - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward stop position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6196 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, route the wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion frame. - 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. 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. For additional information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Testing and Inspection/Component Tests and General Diagnostics. - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Service and Repair/Occupant Classification Sensor (OCS) System Reset. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Power seat shown, manual seat similar. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 3. Disconnect the seat position sensor electrical connector. 4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6204 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 6205 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 6208 Air Bag Control Module: Diagrams Restraints Control Module (RCM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 6209 Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Driver Can Vent Unit > Page 6210 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 6211 Air Bag Control Module: Service and Repair Restraints Control Module (RCM) Removal WARNING: Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out Programmable Module Installation (PMI). Failure to follow these instructions may result in component damage and/or system failure. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning NOTE: When installing a new Restraints Control Module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. NOTE: The air bag warning indicator illuminates when the correct RCM fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. If installing a new RCM, carry out the steps necessary to prepare for Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 6212 3. Remove the front floor console. 4. Disconnect the large 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 1. Install the RCM. 2. Install the 3 RCM nuts. - Tighten to 12 Nm (106 lb-in). 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. NOTICE: Putting the large electrical connector into the Restraints Control Module (RCM) on an angle may cause bad electrical connections and damage components. Position the large electrical connector into the RCM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Page 6213 6. Connect the large RCM connector. - NOTICE: Do not push the connector to the point where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the Restraints Control Module (RCM), before using the lever to fully seat the connector. Damage to the connector or component may occur. With the large 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 front floor console. 8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 9. When installing a new RCM, carry out the steps necessary to complete Programmable Module Installation (PMI). See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning 10. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 6217 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Locations > Page 6218 Seat Occupant Classification Module - Air Bag: Service and Repair Occupant Classification System Module (OCSM) NOTE: Power seat shown, manual seat similar. Removal NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Disconnect the Occupant Classification System Module (OCSM) electrical connector underneath the front of the passenger seat. 3. NOTE: Note the position of the locator tab on the OCSM for installation. Remove the 2 screws and the OCSM. 4. To install, reverse the removal procedure. 5. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 6. Carry out the appropriate procedure after installation of an Occupant Classification Sensor (OCS) system component. - If installing the original OCS system component, carry out the OCS System Zero Seat Weight Test and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics. - If installing a new OCS system component, carry out the OCS Reset and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. 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 this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagram. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition to OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6224 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6225 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the cover and RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6226 7. Remove the 2 driver air bag module bolts (1 shown). 8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Open and lower the glove compartment door. 10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield. 11. NOTE: The canister vent and adaptive tether do not require deactivation. Disconnect the LH side passenger air bag module electrical connector. 12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Disengage the passenger seat side air bag module electrical connector locking clip, release the tab and disconnect the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 13. Release and position aside the passenger side C-pillar trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6227 14. Disconnect the passenger side safety canopy module electrical connector. 15. Release and position aside the driver side C-pillar trim panel. 16. Disconnect the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 17. Remove the driver and passenger side upper C-pillar trim panels. 18. Disconnect the passenger side safety canopy module electrical connector. 19. Disconnect the driver side safety canopy module electrical connector. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6228 20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module electrical connector locking clip, release the tab and disconnect the driver seat side air bag module electrical connector. 21. Install the RCM fuse 17 (10A) to the SJB. 22. 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. 3. Connect the driver seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles 4. Connect the driver side safety canopy module electrical connector. 5. Connect the passenger side safety canopy module electrical connector. 6. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 7. Connect the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6229 8. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 11. Connect the passenger seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Attach the passenger seat side air bag module electrical connector to the seat track bracket. 12. Connect the LH side passenger air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6230 13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer. 14. NOTICE: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. 15. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 16. Turn the ignition switch from OFF to ON. 17. Install RCM fuse 17 (10A) to the SJB and install the cover. 18. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 19. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: Second row bucket seats shown, others similar. NOTE: Carpet removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6236 1. Remove the bolt(s) and tether anchor(s). - To install, apply clear silicone rubber and tighten to 40 Nm (30 lb-ft). 2. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6237 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6238 outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the liftgate scuff plate trim panel. 2. Remove the tether anchor bolt(s) and tether anchor(s). - To install, apply clear silicone rubber and tighten to 40 Nm (30 lb-ft). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation Seat Belt Buckle: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing any active occupant restraint components, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Buckles Safety belt buckle and pretensioner The safety belt buckle and pretensioners are located on the inboard side of the seat track and is for front seat occupants. The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt system when deployed. When the pretensioner deploys, the buckle moves downward, removing excess webbing from the lap and shoulder safety belts. If the vehicle is involved in a crash that results in pretensioner deployment, a new safety belt buckle pretensioner must be installed. For safety belt buckle pretensioner diagnosis and disposal information, refer to Diagnosis and Testing or General Procedures in Air Bag Systems. See: Air Bag Systems/Testing and Inspection Second and third row safety belt buckles The second and third row safety belt buckles are attached to the seat cushion frames or floor and can be serviced separately. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Description and Operation > Page 6242 Seat Belt Buckle: Testing and Inspection Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Buckle and Tongue The safety belt buckle and tongue assembly must operate freely during the latching and unlatching function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion). 1. Verify the following during the latching sequence: - Tongue insertion is not hindered by excessive effort. - A click is heard when the safety belt buckle latches the tongue. 2. Verify the system integrity by forcefully pulling on the safety belt webbing. 3. Unlatch the safety belt by fully depressing the safety belt buckle release button and allowing the safety belt to release and retract. 4. Verify the following during the unlatching process: - Push-button depression does not require excessive effort. - The tongue can be removed easily from the buckle. 5. Repeat the above steps 3 times. 6. If the functional test reveals a concern(s), install a new safety belt buckle or safety belt retractor as required. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Tilt the second row seat forward. 2. Remove the seat base cover. 3. Remove the bolt and safety belt buckle. - To install, apply clear silicone rubber and tighten to 47 Nm (35 lb-ft). 4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6245 To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6246 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6247 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Center And RH, 60/40, E-Z Entry Safety Belt Buckle - Second Row, Center and RH, 60/40, E-Z Entry Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6248 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the 40 percent seat. 2. Remove the bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 3. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6249 Seat Belt Buckle: Service and Repair Safety Belt Buckle - Second Row, Bucket Safety Belt Buckle - Second Row, Bucket Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Tilt the second row seat forward. 2. Remove the seat base cover. 3. Remove the bolt and safety belt buckle. - To install, apply clear silicone rubber and tighten to 47 Nm (35 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6250 4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6251 3. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Safety Belt Buckle - Second Row, Center And RH, 60/40, E-Z Entry Safety Belt Buckle - Second Row, Center and RH, 60/40, E-Z Entry Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Safety Belt Buckle - Second Row, LH, 60/40, Bench Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6252 Safety Belt Buckle - Second Row, LH, 60/40, Bench Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the 40 percent seat. 2. Remove the bolt and safety belt buckle. - To install, tighten to 55 Nm (41 lb-ft). 3. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6253 Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Safety Belt Buckle - Third Row Safety Belt Buckle - Third Row Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6254 Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: Power seat shown, manual seat 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 4. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Safety Belt Buckle And Pretensioner Safety Belt Buckle and Pretensioner NOTE: LH shown, RH similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6255 Removal and Installation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the seat so it does not engage the safety belt buckle and pretensioner bracket and allows access to all 4 seat mounting fasteners. - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Safety Belt Buckle - Second Row, Bucket > Page 6256 2. Remove the 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 7. Install the seat and repower the SRS. If the passenger seat has been serviced, do not prove out the SRS at this time. 8. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 6261 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 6264 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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 shoulder height adjuster to the most downward position. 5. Remove the bolt. - To install, tighten to 40 Nm (30 lb-ft). 6. Remove the safety belt shoulder height adjuster. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6268 1. Rotate the safety belt shoulder height adjuster downward to release the lower tab. 2. Remove the safety belt shoulder height adjuster. 7. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 8. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing any active occupant restraint components, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Warning System The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis and Testing, Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to Diagnosis and Testing, Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation > Page 6272 Seat Belt Reminder Buzzer: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the scan tool. 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and the front passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the ON position (do not start the engine). 2. Wait until the safety belt warning indicator turns off (approximately 1 minute). 3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt 9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning indicator illuminates for 3 seconds. 4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second flash sequence after a brief pause. 5. After confirmation, the deactivation/activation procedure is complete. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing any active occupant restraint components, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Warning System The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis and Testing, Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to Diagnosis and Testing, Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 6276 Seat Belt Reminder Lamp: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the scan tool. 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and the front passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the ON position (do not start the engine). 2. Wait until the safety belt warning indicator turns off (approximately 1 minute). 3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt 9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning indicator illuminates for 3 seconds. 4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second flash sequence after a brief pause. 5. After confirmation, the deactivation/activation procedure is complete. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation Seat Belt Retractor: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing any active occupant restraint components, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Retractors - Adaptive load limiting retractor (front only) - Dual locking mode Emergency Locking Retractor (ELR) - Automatic Locking Retractor (ALR) (all except driver seat) Adaptive load limiting Adaptive load limiting safety belt retractors are pyrotechnic devices integrated with the driver and front passenger safety belt retractor assemblies. Adaptive load limiting safety belt retractors work in conjunction with the safety belt buckle pretensioners to control the tension of the driver and front passenger safety belts. The Restraints Control Module (RCM) monitors the readiness of the adaptive load limiting safety belt retractor. The RCM uses this information and all other information provided by the restraints system to determine what action is to be taken. For adaptive load limiting safety belt retractor diagnostic information, refer to Diagnosis and Testing in Air Bag Systems. See: Air Bag Systems/Testing and Inspection Automatic Locking Retractor (ALR) The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is automatically activated when the safety belt webbing is fully extracted from the retractor and then allowed to retract. As the safety belt webbing is retracted back onto the spool, an audible clicking sound is made indicating the safety belt retractor is in ALR mode and the safety belt webbing will not pull back out of the safety belt retractor. To disengage the ALR mode, allow the safety belt webbing to fully retract back onto the spool. The ALR mode is disengaged when the webbing is free to extract and retract back into the retractor. For testing, refer to the appropriate Functional Test procedure Diagnosis and Testing in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Emergency Locking Retractor (ELR) The ELR is a vehicle-sensitive feature designed to activate and lock the safety belt webbing during hard braking, hard cornering or in an impact of approximately 24 km/h (15 mph). The ELR feature helps to reduce the forward movement of the driver and passengers. For testing, refer to the appropriate Functional Test procedure Diagnosis and Testing in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Retractor The safety belt retractor must be freely operational for extraction and retraction of the safety belt webbing between full extension and in-vehicle stowed positions. 1. Extract and retract the safety belt between the full extension and stowed positions. 2. Verify the safety belt retractor operates without excessive effort or binding. 3. Install a new safety belt retractor if any concern is found or the complaint has been verified. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor > Page 6282 Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode 1. Position the seat backrest fully upright (if adjustable). 2. Position the safety belt shoulder height adjuster (if equipped) in the full down or up position. 3. Fasten the safety belt. 4. Pull out the safety belt webbing until the Automatic Locking Retractor (ALR) feature is activated. 5. Allow the safety belt webbing to retract until it stops. 6. Pull on the safety belt webbing to check that the safety belt retractor has remained in the ALR mode. If the safety belt retractor is not locked, install a new safety belt retractor. 7. Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position. 8. Pull out and retract the safety belt webbing to verify the safety belt retractor has converted automatically out of ALR mode. If the safety belt retractor remains locked in the ALR mode, install a new safety belt retractor. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Testing and Inspection > Functional Test - Safety Belt Retractor > Page 6283 Seat Belt Retractor: Testing and Inspection Functional Test - Safety Belt Retractor, Road Test Inspection Safety Belt System Component Test WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test - Safety Belt Retractor, Road Test Inspection WARNING: The driver and passenger must be prepared to brace themselves in the event the safety belt retractor does not lock. Failure to follow this instruction may result in serious personal injury. NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during testing. NOTE: Do not jerk on the safety belt webbing when carrying out this test. 1. Test the safety belts in the following sequence: 1. Fasten the safety belts and proceed to a safe area. 2. Attain a speed of 24 km/h (15 mph). 3. WARNING: Apply maximum brake force only on dry concrete or equivalent hard surface, NEVER on wet pavement or gravel. Failure to follow this instruction may result in serious personal injury. Grasp the shoulder harness, lean forward and apply the brakes, making a maximum braking application without a skid. 4. The safety belts should lock up with minimum webbing extension. 5. If there is a lockup of all safety belt retractors being tested, the safety belt retractors are functioning correctly. If any safety belt retractor fails to lock up, install a new safety belt retractor(s). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6286 NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: 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 Supplemental Restraint System (SRS). For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Air Bag Systems. 3. Remove the safety belt anchor cover. 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 lower B-pillar trim panel. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 12. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Air Bag Systems. 13. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6287 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the second row, 40 percent seat. 2. Remove the bolt and safety belt anchor. - To install tighten to 121 Nm (89 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6288 3. NOTE: LH shown, RH similar. Remove the 4 screws and position aside the latch covers. 4. Remove the safety belt guide cover. 5. If equipped, remove the 3 screws and the upper latch cover. 6. Release the J-clip at the bottom of the seat backrest. 7. Remove all the staples in the backrest support panel. 8. NOTICE: 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. 9. Position aside the backrest foam pad. 10. Remove the safety belt retractor cover. 11. Remove the bolt and safety belt retractor. - To install, tighten to 75 Nm (55 lb-ft). 12. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 13. Check the active restraint system for correct operation. For additional information, refer to Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6289 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: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6290 After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 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. NOTICE: 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. 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 11. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6291 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Second Row, Outboard Safety Belt Retractor - Second Row, Outboard Explorer/Mountaineer Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6292 Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. Explorer/Mountaineer and Explorer Sport Trac with 60/40 bench seat 1. Remove the seat. Explorer Sport Trac 2. Remove the trim panels. Explorer/Mountaineer with 60/40 E-Z entry seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6293 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 11. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6294 Seat Belt Retractor: Service and Repair Safety Belt Retractor - Third Row Safety Belt Retractor - Third Row Removal and Installation WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. 1. Remove the quarter trim panel. 2. Remove the bolt and D-ring. - To install, tighten to 40 Nm (30 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Safety Belt Retractor - Front > Page 6295 3. Remove the bolt and safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. For additional information, refer to the appropriate Functional Test procedure in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6300 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6301 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6302 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Safety Belt Retractor Pretensioner > Page 6303 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 6304 Seat Belt Tensioner: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing any active occupant restraint components, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Retractors - Adaptive load limiting retractor (front only) - Dual locking mode Emergency Locking Retractor (ELR) - Automatic Locking Retractor (ALR) (all except driver seat) Adaptive load limiting Adaptive load limiting safety belt retractors are pyrotechnic devices integrated with the driver and front passenger safety belt retractor assemblies. Adaptive load limiting safety belt retractors work in conjunction with the safety belt buckle pretensioners to control the tension of the driver and front passenger safety belts. The Restraints Control Module (RCM) monitors the readiness of the adaptive load limiting safety belt retractor. The RCM uses this information and all other information provided by the restraints system to determine what action is to be taken. For adaptive load limiting safety belt retractor diagnostic information, refer to Diagnosis and Testing in Air Bag Systems. See: Air Bag Systems/Testing and Inspection Automatic Locking Retractor (ALR) The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is automatically activated when the safety belt webbing is fully extracted from the retractor and then allowed to retract. As the safety belt webbing is retracted back onto the spool, an audible clicking sound is made indicating the safety belt retractor is in ALR mode and the safety belt webbing will not pull back out of the safety belt retractor. To disengage the ALR mode, allow the safety belt webbing to fully retract back onto the spool. The ALR mode is disengaged when the webbing is free to extract and retract back into the retractor. For testing, refer to the appropriate Functional Test procedure Diagnosis and Testing in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Emergency Locking Retractor (ELR) The ELR is a vehicle-sensitive feature designed to activate and lock the safety belt webbing during hard braking, hard cornering or in an impact of approximately 24 km/h (15 mph). The ELR feature helps to reduce the forward movement of the driver and passengers. For testing, refer to the appropriate Functional Test procedure Diagnosis and Testing in Safety Belt System See: Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 6308 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor Impact Sensor: Locations RH Front Impact Severity Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6314 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6315 Impact Sensor: Locations LH Front Impact Severity Sensor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6316 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6317 Impact Sensor: Locations Side Impact Sensor, Second Row Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6318 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6319 Impact Sensor: Locations Side Impact Sensor, Second Row Passenger Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6320 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6321 Impact Sensor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6322 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6323 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6324 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6325 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6326 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6327 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6328 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6329 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > RH Front Impact Severity Sensor > Page 6330 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6333 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6334 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6335 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6336 Impact Sensor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6337 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Side Impact Sensor, First Row Driver Side > Page 6338 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the 4 pin-type retainers and lower radiator air deflector. 3. Disconnect the electrical connector. 4. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Remove the bolt and front impact severity sensor. To install, tighten to 12 Nm (106 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6341 5. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6342 Impact Sensor: Service and Repair Side Impact Sensor - C-Pillar Side Impact Sensor - C-Pillar, Explorer Sport Trac NOTE: RH shown, LH similar. WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: The RH and LH C-pillar mounted side impact sensors are not interchangeable. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6343 - 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. NOTE: Note the position of the sensor and bracket locating tab for installation. NOTE: 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 (106 lb-in). 7. Disconnect the electrical connector and remove the side impact sensor. 8. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 9. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Severity Sensor > Page 6344 Impact Sensor: Service and Repair Side Impact Sensor - Front Door Side Impact Sensor - Front Door NOTE: LH side shown, RH similar. Removal and Installation WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to the original production configuration. A new RCM and sensors must be installed whether or not the air bags have deployed. Failure to follow these instructions may result in serious personal injury or death in a crash. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 2. Remove the front interior door trim panel. 3. Detach the rearward lower corner of the weathershield on the door to access the side impact sensor (pressure sensor). 4. Disconnect the electrical connector. 5. Remove the bolt and side impact sensor. - To install, tighten to 9 Nm (80 lb-in). 6. WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. To install, reverse the removal procedure. 7. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Safety Belt Buckle Switch, Passenger > Page 6349 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Diagrams > Safety Belt Buckle Switch, Driver > Page 6352 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > OCS Rail 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > OCS Rail 1 > Page 6357 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6358 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor NOTE: Outboard Occupant Classification Sensor (OCS) rail shown, inboard similar. Removal WARNING: The occupant classification sensor (OCS) rails have a built-in strain gauge which may operate incorrectly if an OCS rail is dropped by itself, dropped after it is installed to the front passenger seat or dropped after it is installed to a front passenger seat track assembly. Use care when handling an OCS rail before or after it is installed to the front passenger seat or seat track assembly. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. WARNING: Do not disassemble the occupant classification sensor (OCS) rail or tighten or loosen any of the nuts and bolts installed to the OCS rail body. Only the 8 bolts that attach the 2 OCS rails to the seat track may be removed and installed. Failure to follow these instructions may result in incorrect operation of the OCS system and increase the risk of serious personal injury or death in a crash. WARNING: Never allow oil, grease, water or foreign contaminants to get on/in the occupant classification sensor (OCS) components or electrical connectors. Failure to follow this instruction may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. WARNING: Use care when handling the front passenger seat and track assembly. Dropping the assembly, placing excessive weight on or sitting on a front passenger seat that is not secured in the vehicle may result in damaged seat components. Failure to follow these instructions may result in incorrect operation of the occupant classification sensor (OCS) system and increases the risk of serious personal injury or death in a Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6359 crash. NOTICE: Prevent oil and/or grease from getting on the Occupant Classification Sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Remove the front passenger seat. 2. NOTICE: Before releasing the Occupant Classification Sensor (OCS) rail electrical connector, push only on the tip of the connector release tab to release the electrical connector. Do not insert the tool too deep into the OCS rail electrical connector or damage to the electrical connector may occur. NOTE: Note the Occupant Classification Sensor (OCS) rail position, electrical wiring routing, wiring, connector and wiring retainers for installation. On the affected side, detach the 2 OCS rail wiring retainers and 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 stop position. - If equipped with a power seat track, apply power and ground to the pins shown. 5. Remove the 2 rear bolts from the OCS rail. 6. Move the seat to the rearward stop position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6360 7. NOTE: Note the locator tab position where the OCS rail goes through the rail shield and into the rear seat track mounting point for installation. Remove the 2 front bolts and OCS rail and shield. Installation NOTE: If installing a new seat track, position the seat track where the seat will be in the full rearward position before installing the OCS rails. NOTE: To make sure of correct installation, the OCS rail bolts must be installed in the sequence shown. 1. WARNING: To prevent foreign material and contaminants from entering the occupant classification sensor (OCS) rail, make sure the OCS rail shield is present, is not damaged and is correctly installed to the OCS rail. Failure to follow these instructions may result in incorrect operation of the OCS system and increases the risk of serious personal injury or death in a crash. NOTICE: Prevent oil and/or grease from getting on the Occupant Classification Sensor (OCS) rail bolts as this can lead to tightening beyond the specified torque value. Failure to follow this instruction may result in damaged or broken OCS rail bolts. NOTE: Make sure the OCS rail shield is seated correctly on the OCS rail. Install the shield on the OCS rail, and install the OCS rail and shield on the seat track with the locator tab aligned correctly as shown. 2. Hold the OCS rail and shield firmly in position and install the front mounting position rear bolt. - Tighten to 25 Nm (18 lb-ft). 3. Hold the OCS rail and shield firmly in position and install the front mounting position front bolt. - Tighten to 25 Nm (18 lb-ft). 4. Move the seat to the forward stop position. - If equipped with a power seat track, apply power and ground to the pins shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams > Page 6361 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, route the wiring and attach the 2 wiring retainers. 7. Center the seat track to the seat cushion frame. - 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. 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. For additional information, refer to Occupant Classification Sensor (OCS) System Zero Seat Weight Test See: Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics. - If installing a new OCS system component, carry out the Occupant Classification Sensor (OCS) System Reset procedure and prove out the SRS. For additional information, refer to Occupant Classification Sensor (OCS) System Reset See: Air Bag Systems/Service and Repair/Occupant Classification Sensor (OCS) System Reset. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Power seat shown, manual seat similar. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. 1. Position the front seat to the rearmost and upward position. 2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. 3. Disconnect the seat position sensor electrical connector. 4. WARNING: Always tighten the seat position sensor retaining bolt to specified torque. Failure to do so may result in incorrect restraint system operation, which increases the risk of personal injury or death in a crash. Remove the bolt and seat position sensor. To install, tighten to 6 Nm (53 lb-in). 5. To install, reverse the removal procedure. 6. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 6368 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6374 Accessory Delay Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6375 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Vehicles Without Navigation NOTE: Instrument panel shown removed for clarity. Vehicles With Navigation NOTE: Glove compartment shown removed for clarity. Removal and Installation NOTE: Vehicles without navigation only have an upper satellite radio antenna cable. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Satellite Radio > Page 6382 Lower cable (vehicles with navigation) NOTE: The lower satellite antenna cable is only serviceable by cutting the ends off the existing antenna cable and taping them to prevent NVH concerns. The new cable should be overlaid on the electrical harness and secured, as necessary. 1. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control Module (ACM) See: Cellular Phone/Communications Control Module/Service and Repair/Removal and Replacement/Audio Control Module (ACM). Upper cable (all vehicles) 2. Remove the RH A-pillar trim panel. 3. Disconnect the satellite antenna electrical connector. Both cables 4. NOTE: Lower the glove compartment completely to access the connection. Disconnect the upper satellite radio antenna cable from the Satellite Digital Audio Receiver System (SDARS) module (vehicles without navigation) or the lower satellite radio antenna cable (vehicles with navigation). 5. Remove the satellite radio antenna cable. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Antenna Cable - Satellite Radio > Page 6383 Antenna Cable: Service and Repair Antenna Lead-In Cable Antenna Lead-In Cable Removal and Installation 1. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control Module (ACM) See: Cellular Phone/Communications Control Module/Service and Repair/Removal and Replacement/Audio Control Module (ACM). 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 (V6-4.0L (2009)) 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 opening cover. 2. Remove the ignition lock cylinder. 3. Remove the 3 screws and the lower steering column shroud. 4. Remove the Passive Anti-Theft System (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 (IC) again. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 6395 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 6396 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 3 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 6397 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter Programming Remote Keyless Entry (RKE) Transmitter Programming NOTE: All Remote Keyless Entry (RKE) transmitters must be programmed at the same time. NOTE: 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 the 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 Locks, Latches and Entry Systems See: Body and Frame/Locks/Power Locks/Testing and Inspection. Make sure that no more than the maximum number of 6 RKE transmitters are attempted to be programmed. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 6402 Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming Autolock and Auto-Unlock 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 6403 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 6404 Keyless Entry Transmitter: Testing and Inspection 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 6405 Keyless Entry Transmitter: Testing and Inspection 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 6406 Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming Stepped Unlock Programming 1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the Remote Keyless Entry (RKE) transmitter simultaneously for 4 seconds. The parking lamps will flash twice to indicate the mode change. 2. Repeat Step 1 to enable/disable the stepped unlocking feature. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality Technical Service Bulletin # 10-25-12 Date: 101223 SYNC(R) System - Poor Cell Phone Audio Quality TSB 10-25-12 12/23/10 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the jumper harness. ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. 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 MT102512 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Service Procedure Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6416 The following procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS. Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR, 9L2T-14D544-BE with E911/VHR or later version. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement and the service procedure should not be performed. Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900 to prevent interior squeak/rattle noise. a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place the microphone as close to trim as possible to help minimize visible wire. Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6417 ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable up through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Escape / Mariner 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6418 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Navigator / Expedition 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the female side of the connector (17C712 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6419 ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-150 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6420 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-Super Duty 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used 7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6421 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Focus 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 10) Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim. 2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6422 3. Route microphone cable up through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Fusion / Milan / MKZ 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time proceed to Final Test / Service Steps. Taurus / Sable / Taurus X Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6423 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6424 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C911 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. Final Test / Service Steps 1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the jumper inline connector before connecting the microphone. ^ Jumper blue wire equal 12V positive. ^ Jumper black wire equal ground reference. ^ Jumper yellow wire equal microphone return signal circuit less than IV. 2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make sure that the connector tabs have locked together after connecting. Reversing this connector would cause a failure of the microphone. 3. Bundle and tuck the remainder of the microphone cable over the front of the headliner. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Cellular Phone Microphone: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6429 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6430 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6431 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6432 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6433 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6434 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6435 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6436 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6437 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6438 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6439 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality Technical Service Bulletin # 10-25-12 Date: 101223 SYNC(R) System - Poor Cell Phone Audio Quality TSB 10-25-12 12/23/10 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Fusion, Taurus X, Taurus 2008-2011 Focus 2008-2010 Edge, Explorer Sport Trac, Explorer 2009-2010 F-150, F-Super Duty, Flex 2009-2011 Escape, Expedition LINCOLN: 2008-2009 MKZ 2009-2011 MKS 2008-2010 MKX 2009-2011 Navigator MERCURY: 2008-2009 Milan, Sable 2008-2010 Mountaineer 2009-2011 Mariner This article supersedes TSB 10-8-4 to update the vehicle model years, Service Procedure and the Part List. The new SYNC service Microphone kit now includes a voltage filter incorporated into the jumper harness. ISSUE Some customers of 2008-2011 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. 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 MT102512 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Service Procedure Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6445 The following procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO VEHICLES EQUIPPED WITH HEADLINER MICROPHONE OR DEALER-INSTALLED SYNC SYSTEMS. Go to Step 2 if the vehicle is already equipped with SYNC 3.0 Traffic and Directions or has already been upgraded to latest available consumer interface processor (CIP) level 9L3T-14D544-AE without E911/VHR, 9L2T-14D544-BE with E911/VHR or later versions. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-1 4D544-AE without E9 11 /VHR, 9L2T-14D544-BE with E911/VHR or later version. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement and the service procedure should not be performed. Instead, refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. The jumper harness is equipped with a voltage filter. The filter will need to be wrapped in soft foam 164-R4901 or flock tape 164-R4903 from the Rotunda squeak and rattle kit 164-R4900 to prevent interior squeak/rattle noise. a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place the microphone as close to trim as possible to help minimize visible wire. Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6446 ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable up through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C210. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Escape / Mariner 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6447 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two of the three black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD182 from C214. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD1 82. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Navigator / Expedition 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped) or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN07, RMNO7 and DMN07 (shield) from C298. Cut the three circuits on the female side of the connector (17C712 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C298. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6448 ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMNO7, RMNO7 and DMNO7 (shield) from C248 (Sport Trac uses C260). Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO7 and any two (of the three) black jumper harness wires to RMNO7 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO5 and GD143 from C248. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO5 and the remaining black jumper harness wire to GD143. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-150 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 from C315 and GD133 from C314. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6449 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. F-Super Duty 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C264. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used 7. Identify circuits CBP41 and GD133 from C264. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6450 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Focus 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 10) Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the interior lamp trim. 2. Lower the interior lamp assembly. Refer to WSM, Section 417-02 for additional information. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6451 3. Route microphone cable up through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install interior lamp assembly; ensure microphone cable enters the interior lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CPL6O and GD161 from C934. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CPL6O and the remaining black jumper harness wire to GD161. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test / Service Steps. Fusion / Milan / MKZ 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMM13, RMM13 and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMM13 and any two (of the three) black jumper harness wires to RMM13 and DMM13 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBPO2 and GD139 from C913. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBPO2 and the remaining black jumper harness wire to GD139. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time proceed to Final Test / Service Steps. Taurus / Sable / Taurus X Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6452 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMN02 and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMN02 and any two (of the three) black jumper harness wires to RMN02 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C925. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-25-12 > Dec > 10 > SYNC(R) System - Poor Cell Phone Audio Quality > Page 6453 2. Lower the overhead console. Refer to WSM, Section 501-12 for additional information. 3. Route microphone cable through existing hole in the headliner and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124 for links to location and connector views. 6. Identify circuits VMN02, RMNO2 and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C911 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM Section 417-01 for additional information. These are the microphone positive, negative and shield circuits. Then splice the yellow jumper harness wire to VMNO2 and remaining black jumper harness wires to RMNO2 and DMNO7 (shield). Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 7. Identify circuits CBP41 and GD133 from C911. This is power and ground for both the new microphone and the existing mirror. Splice in the blue jumper harness wire to CBP41 and the remaining black jumper harness wire to GD133. Ensure that the original circuits remain intact and connected as this is power for other items within the rear view mirror and in the roof. 8. Do not plug in the microphone at this time, proceed to Final Test I Service Steps. Final Test / Service Steps 1. After splicing/soldering is complete, apply power to the vehicle and confirm the voltage at the jumper inline connector before connecting the microphone. ^ Jumper blue wire equal 12V positive. ^ Jumper black wire equal ground reference. ^ Jumper yellow wire equal microphone return signal circuit less than IV. 2. Turn off ignition and attach the microphone connector to the jumper harness connector. Make sure that the connector tabs have locked together after connecting. Reversing this connector would cause a failure of the microphone. 3. Bundle and tuck the remainder of the microphone cable over the front of the headliner. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Cellular Phone Microphone: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6458 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6459 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6460 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6461 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6462 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6463 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6464 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6465 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6466 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6467 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6468 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 10-2-8 > Feb > 10 > SYNC(R) System Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 6481 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-26-8 > Jan > 10 > SYNC(R) System Software Update For Various Concerns > Page 6482 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set > Page 6487 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System Functions Inoperative/DTC's Set > Page 6488 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6498 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6499 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6504 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6505 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift Engine Control Module: All Technical Service Bulletins Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift TSB 09-18-10 09/21/09 DRIVELINE BUMP WHILE BRAKING BELOW 15 MPH (24 KM/H) - HARSH 1-2 UPSHIFT - BUILT BEFORE 10/1/2008 FORD: 2009 Explorer Sport Trac, Explorer MERCURY: 2009 Mountaineer ISSUE Some 2009 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with a 6R80 transmission and built prior to 10/1/2008 may exhibit a bump feeling while braking to a stop below 15 MPH (24 Km/h) and some vehicles a harsh 1-2 upshift. A later calibration is available to improve these conditions. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Install Integrated Diagnostic System (IDS)/Portable Diagnostic Software (PDS) or equivalent and start a session, identify (ID) vehicle. 2. Update the powertrain control module (PCM)/transmission control module (TCM) calibration using IDS release 62.11 and higher. This new calibration is included in the VCM 2009.7 DVD. Calibration files may also be obtained at the website. The TCM cannot be independently reprogrammed. Reprogram using the programmable module installation (PMI) function to ensure that engine and transmission calibrations are updated to the latest level simultaneously. In some cases it maybe helpful to ^ Disconnect the TCM connector. ^ Start a new IDS session. ^ Perform PMI on the PCM. ^ Once IDS instructs to install the new module in the vehicle, plug the TCM in and follow the prompts. a. Verify that the TCM calibration shows 9L2P-7J104-AG part number after reprogramming is complete. b. Select the following from the IDS tool: (1) Toolbox. (2) Powertrain. (3) OBD Test Modes. (4) Mode 9 Vehicle Information. (5) TCM Cal Part Number. 3. Clear TCM keep alive memory (KAM) and adaptive tables. a. Using IDS: (1) Open Toolbox. (2) Choose Powertrain. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 6511 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 6512 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 6518 (3) Choose Reset KAM. (4) Choose TCM. b. Using PDS: (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. 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 (24Km/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 ensuring that the 1-2, 2-3 and 3-4 shifts occur at engine speeds between 1600-2000 RPM. e. Continue to accelerate until you achieve 50 MPH (80 Km/h) or the 5-6 upshift. f. Brake gently to a complete stop and hold foot on brake for ten (10) seconds. g. Repeat steps (d-f) three (3) times. NOTE THE HARSH BUMP FELT WHILE BRAKING TO A STOP WILL BE IMPROVED. HOWEVER, SEVERAL DAYS OF DRIVING ARE 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 091810A 2009 Explorer, 1.0 Hr. Mountaineer, Explorer Sport Trac 6R80 Transmission: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 09-18-10 > Sep > 09 > Engine, A/T Controls - Driveline Bump/Harsh 1-2 Shift > Page 6519 DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6522 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6525 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6526 Communications Control Module: Diagrams Audio Control Module (ACM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6527 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6528 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures Communications Control Module: Procedures Accessory Protocol Interface Module (APIM) Software Level Check Accessory Protocol Interface Module (APIM) Software Level Check NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM) Programming in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current APIM software level. - The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. The scan tool displays the following information: - Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM - Installed date: date the APIM was installed - Radio: currently identified ACM in the vehicle - HW Part No.: APIM hardware part number - Un-installed date: date (if any) the APIM was uninstalled - S/N: APIM serial number - Last Recorded State - Software Date/Time: date and time of last recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6531 - Description: a description of the content of the software revision - History - Software Date/Time: date and time of any recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time - Description: a description of the content of the software revision - Available Software for Programming Select: allows the software package to be selected - Lineage: the original software release, if the software available is a revision - VIP: VIP software level that is available with the selection - CIP: CIP software level that is available with the selection - Description: a description of the content of the software revision 9. Click a CIP software level to view the device compatibility list associated with the CIP software level, if desired. 10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port, or exit the OASIS screen. Audio Control Module (ACM) Self-Diagnostic Mode Audio Control Module (ACM) Self-Diagnostic Mode Audio Systems Without Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after Step 3 by turning the ACM off. Before the speaker walk test is complete, carry out any of the following actions: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6532 5. To exit the self-diagnostic mode, turn the ACM off. Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval - Vehicles Without Navigation 1. Operate the audio system in satellite radio mode. 2. Press and hold the AUX button and preset button 1, simultaneously. - The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN) displays on the screen. 3. Record the SDARS module ESN. 4. Turn the audio system off. Audio Systems With Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this step, or by allowing the speaker walk test to complete on its own. Before the speaker walk test is complete, press the "End Test" selection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6533 5. The following tests are available through the "BEZEL DIAGNOSTICS" menu: 6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL DIAGNOSTICS" menu. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6534 Communications Control Module: Removal and Replacement Audio Control Module (ACM) Audio Control Module (ACM) Removal and Installation NOTE: It is not necessary to remove the Audio Control Module (ACM) to retrieve the part number. For additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode See: Procedures/Audio Control Module (ACM) Self-Diagnostic Mode. 1. NOTE: Module configuration is required when a new ACM is being installed. Upload the ACM configuration information to the scan tool. 2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM. - Disconnect the ACM electrical connectors. 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Floor Console Components Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6535 Accessory Protocol Interface Module (APIM) Removal and Installation 1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software and hardware level when a new APIM is being installed to make sure that the new component is the same version as the component being replaced. Retrieve and record the current APIM software and hardware level. For additional information, refer to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory Protocol Interface Module (APIM) Software Level Check. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6536 2. Remove the 4 screws and the front floor console stowage door. 3. Remove the 2 screws and the front floor console rear trim panel. - Pull straight back to disengage the clips. 4. Remove the 2 screws and the front floor console finish panel. - Pull straight up to disengage the clips. 5. Remove the front floor console stowage bin. - Remove the 4 screws. - Disconnect the audio input jack electrical connector. - Disconnect the Universal Serial Bus (USB) port electrical connector. - Disconnect the APIM electrical connector. - Disconnect the USB cable electrical connector (at the APIM). 6. Remove the 4 screws and the APIM. 7. To install, reverse the removal procedure. - If a new APIM is being installed, program the APIM to the correct software level. Universal Serial Bus (USB) Cable and Port Universal Serial Bus (USB) Cable and Port Floor Console Components Universal Serial Bus (USB) Cable And Port-To-Bezel Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6537 USB Cable And Port-To-Accessory Protocol Interface Module (APIM) Removal and Installation 1. Remove the 4 screws and the front floor console stowage door. 2. Remove the 2 screws and the front floor console rear trim panel. - Pull straight back to disengage the clips. 3. Remove the 2 screws and the front floor console finish panel. - Pull straight up to disengage the clips. 4. Using a suitable tool (such as a trim removal tool) pry the audio input jack bezel from the storage bin. - Disconnect the audio input jack electrical connector. 5. Disconnect the Universal Serial Bus (USB) port connector from the audio input jack bezel. 6. Remove the 4 screws and the front floor console stowage bin. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6538 7. Remove the USB cable and port. - Disconnect the electrical connector. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6543 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6544 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6545 Parking Assist Control Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6546 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6547 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 6548 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) - Explorer Sport Trac Removal and Installation 1. Remove the cab rear trim panel. 2. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker clips. - Remove the parking aid speaker. 3. If replacing the Parking Aid Module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM screw. - Remove the PAM. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6553 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6554 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6555 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6556 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6557 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6558 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6559 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6562 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6563 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 6564 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 6565 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Mountaineer, Explorer Sport Trac NOTE: Mountaineer shown, Explorer Sport Trac similar. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams Parking Assist Warning Indicator: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Diagrams > Page 6569 Parking Assist Warning Indicator: Service and Repair Parking Aid Speaker Removal and Installation 1. Remove the LH C-pillar trim panel. 2. Remove the bolt and the speaker and bracket assembly. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations > Page 6573 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure Driver/Vehicle Information Display: Reset Procedure Message Center Configuration Oil Life Reset And Start Value - With Message Center NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Without Message Center NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 6576 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6585 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6586 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6591 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6592 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6593 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6594 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6595 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6596 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6597 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6598 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6599 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6600 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6601 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6607 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6608 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6613 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6614 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6615 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6616 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6617 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6618 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6619 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6620 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6621 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6622 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6623 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6628 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6629 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6635 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6636 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6637 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6638 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6644 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6645 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6646 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-12-12 > Jun > 09 > A/T - Loss Of 2nd/3rd/5th Gears/Ratio DTC's Set > Page 6647 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams > Page 6652 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 6666 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 6667 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair Entertainment System Control Panel: Service and Repair Rear Entertainment Module (RETM) Removal NOTE: Module configuration is required when a new Rear Entertainment Module (RETM) is being installed. 1. Upload the RETM configuration to the scan tool. 2. NOTE: Open the RETM display. Remove the 4 screws. 3. Remove the RETM. - Pull down on the sides of the RETM to disengage the clips from the bracket. - Using a suitable tool (such as a flat-bladed screwdriver), push the rear most U-hook forward and release the U-hooks. - Hang the RETM on the J-hooks and disconnect the electrical connector. - Remove the RETM from the J-hooks. Installation 1. Hang the RETM on the J-hooks. 2. Connect the electrical connector. 3. Remove the RETM from the J-hooks. 4. NOTE: Tilt the RETM, as necessary, to align it correctly. Align the left side guide pin with the left side locating hole. 5. Lift up the right side of the RETM and engage the U-hooks. 6. Install the 4 screws. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Panel > Component Information > Service and Repair > Page 6671 7. Push on the left and right sides of the RETM to engage the clips. 8. Download the RETM configuration from the scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 6675 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations > Page 6676 Garage Door Opener Transmitter: Description and Operation Universal Transmitter Vehicles With Roof Opening Panel and Auxiliary A/C The universal transmitter is an integral part of the LH sun visor. All Other Vehicles The universal transmitter is an integral part of the overhead console. The universal transmitter 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 (V6-4.0L (2009)) 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 Special Tools Used With Diagnostics Universal Transmitter Inspection And Verification Universal Transmitter Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6679 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures Universal Transmitter Symptom Chart Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6680 Garage Door Opener Transmitter: Pinpoint Tests Universal Transmitter Pinpoint Tests Pinpoint Test A: The Universal Transmitter Is Inoperative Refer to Wiring Diagram Set 89, Interior Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Vehicles with roof opening panel and auxiliary A/C will have the universal transmitter located as an integral part of the LH sun visor. For all other vehicles, 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 from the battery saver relay in the Smart Junction Box (SJB) to the universal transmitter through circuit CLN01 (GN/VT) and the universal transmitter is grounded on circuit GD133 (BK). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Universal transmitter - Receiver unit PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- A1 CHECK THE UNIVERSAL TRANSMITTER - Press any of the buttons on the universal transmitter. Does the universal transmitter LED illuminate? Yes GO to A2. No GO to A3. ------------------------------------------------- A2 PROGRAM A HAND-HELD TRANSMITTER INTO THE UNIVERSAL TRANSMITTER - Program the universal transmitter. Refer to Universal Transmitter Programming See: Programming and Relearning. - Does the universal transmitter program successfully? Yes The universal transmitter is OK. VERIFY the receiver operates correctly. No INSTALL a new universal transmitter. For vehicles with roof opening panel and auxiliary A/C, REFER to Headliner in Headliner. For all other vehicles, REFER to Overhead Console in Console. TEST the system for normal operation. ------------------------------------------------- A3 CHECK CIRCUIT CLN01 (GN/VT) FOR AN OPEN - Ignition OFF. - Disconnect: LH Vanity Mirror Lamp C907 (with roof opening panel and auxiliary A/C) or Universal Transmitter C928 (all other vehicles). - Ignition ON. - Measure the voltage between the universal transmitter C907-1 (with roof opening panel and auxiliary A/C) or C928-2 (all other vehicles), circuit CLN01 (GN/VT), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6681 - Is the voltage greater than 10 volts? Yes GO to A4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- A4 CHECK CIRCUIT GD133 (BK) FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the universal transmitter C907-2 (with roof opening panel and auxiliary A/C) or C928-1 (all other vehicles), circuit GD133 (BK), harness side and ground. - Is the resistance less than 5 ohms? Yes INSTALL a new universal transmitter. For vehicles with roof opening panel and auxiliary A/C, REFER to Headliner in Headliner. For all other vehicles, REFER to Overhead Console in Console. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6682 Garage Door Opener Transmitter: Programming and Relearning Universal Transmitter Programming NOTE: A new battery in the hand-held transmitter may allow quicker and easier training due to a more accurate transmission of the radio frequency signal. 1. Verify the hand-held transmitter is operative. 2. Turn the key to the ON position. 3. 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. 4. Select 1 of the 3 universal transmitter buttons to be used for programming. 5. Hold the end of the hand-held transmitter 25-76 mm (1-3 in) away from the front surface of the universal transmitter so that the universal transmitter red light can still be seen. 6. 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 with this type of hand-held transmitter, continue to hold the button on the universal transmitter while pressing and releasing the hand-held transmitter button every 2 seconds. At the same time, press the hand-held transmitter button and the desired button on the universal transmitter until the red light on the universal transmitter flashes first slowly, and then rapidly. Release both buttons when the rapid flashing begins. 7. Firmly press and hold for 5 seconds, then release the just-trained universal transmitter button up to 2 separate times to activate the door. If after 2 separate times, the door still does not activate, press and hold the just-trained universal transmitter button and observe the indicator light. If the indicator light stays on constantly, programming is complete and the device should activate when the universal transmitter button is pressed and released. - If the indicator light blinks rapidly for 2 seconds and then turns to a constant light, follow the Training a Garage Door Opener Equipped With "Rolling Codes" procedure to complete the programming of a rolling code equipped device. Training a Garage Door Opener Equipped With "Rolling Codes" 1. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 2. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) There are 30 seconds to initiate step 3. 3. Return to the vehicle and firmly press, hold for 2 seconds and release the programmed universal transmitter button. Repeat the press/hold/release sequence a second time, and depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming process. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6692 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6693 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6699 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6700 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6705 Memory Positioning Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6706 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6707 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6708 Memory Positioning Module: Service and Repair Driver Seat Module (DSM) Removal and Installation NOTICE: 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 Driver Seat Module (DSM) after installation. 1. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: When a new DSM is installed, it is necessary to download the module configuration information from the scan tool into the new DSM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 6709 To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 6713 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6723 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6724 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6730 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6731 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Pedal Positioning Motor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6736 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 6737 Pedal Positioning Motor: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 6741 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier Amplifier: Diagrams Subwoofer Amplifier Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 6747 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 6748 Amplifier: Diagrams Audio Amplifier Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Subwoofer Amplifier > Page 6749 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6750 Amplifier: Service and Repair Audio Amplifier NOTE: Glove compartment shown removed for clarity. 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 audio amplifier. - Disconnect the electrical connectors. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Customer Interest for Compact Disc Player (CD): > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Compact Disc Player (CD): Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compact Disc Player (CD): > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Compact Disc Player (CD): All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 6768 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control, Audio - Stereo > Component Information > Service and Repair 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. NOTE: When removing the steering wheel controls, disengage the RH side of the controls first. Using a suitable tool (such as a trim removal 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 09-20-10 > Oct > 09 > Audio System Inoperative/Speaker Popping Noise Speaker: Customer Interest Audio System - Inoperative/Speaker Popping Noise TSB 09-20-10 10/19/09 SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac, Explorer, F-Super Duty MERCURY: 2008-2009 Milan, Mountaineer This article supersedes TSB 9-16-3 to update the vehicle lines. ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer, Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM is completely inoperative or will not power on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The speaker pop typically happens after an extended drive period when vehicle is warm and opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be caused by a software lockup event within the ACM. Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not included in the VCM 2009.9 DVD Calibration files may also be obtained at the website. An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a replacement ACM for F-150. 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 092010A 2008-2009 F-Super Duty, 0.3 Hr. Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram The ACM (Do Not Use With Any Other Labor Operations) 092010B 2008 F-150: Retrieve The 0.2 Hr. ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C (Do Not Use With Any Labor Operation Outside Of This Article) 092010C 2008 F-150: Replace The 0.4 Hr. ACM, Can Be Claimed Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 09-20-10 > Oct > 09 > Audio System Inoperative/Speaker Popping Noise > Page 6780 with Operation B (Do Not Use With Any Labor Operation Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise Speaker: All Technical Service Bulletins Audio System - Inoperative/Speaker Popping Noise TSB 09-20-10 10/19/09 SPEAKER POP AND/OR RADIO INOPERATIVE/BLANK/LOCKED UP FORD: 2008-2009 Fusion, Mustang 2008 F-150 2008-2009 Edge, Expedition, Explorer Sport Trac, Explorer, F-Super Duty MERCURY: 2008-2009 Milan, Mountaineer This article supersedes TSB 9-16-3 to update the vehicle lines. ISSUE Some 2008-2009 F-Super Duty, Expedition, Explorer, Explorer Sport Trac, Mountaineer, Fusion, Milan, Mustang,, Edge and 2008 F-150 vehicles equipped with Single CD and CDX6 Audio Control Modules (ACM), may exhibit either a speaker pop noise and/or a condition where the ACM is completely inoperative or will not power on. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE The speaker pop typically happens after an extended drive period when vehicle is warm and opening/closing a door; however, it may happen anytime the (ACM) is turned off. Using the vehicle heater through the instrument panel (IP) panel vents (on high setting) may also cause the condition to repeat more often. The ACM may be completely inoperative, blank. or locked up. It may be caused by a software lockup event within the ACM. Reprogram the ACM to the latest calibration using IDS 63.02 and higher. This new calibration is not included in the VCM 2009.9 DVD Calibration files may also be obtained at the website. An ACM replacement will be necessary for 2008 F-150 for the above symptoms, it can not be reprogrammed with IDS. Reference Workshop Manual, Section 415-00 for removal and installation instructions. Please specify speaker pop noise/lock up on the 1878 form when ordering a replacement ACM for F-150. 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 092010A 2008-2009 F-Super Duty, 0.3 Hr. Expedition, Explorer, Mountaineer, Explorer Sport Trac, Edge, Fusion, Milan, Mustang: Reprogram The ACM (Do Not Use With Any Other Labor Operations) 092010B 2008 F-150: Retrieve The 0.2 Hr. ACM Unit Part Number - Acquire And Order An Exchange Unit Can Be Claimed with Operation C (Do Not Use With Any Labor Operation Outside Of This Article) 092010C 2008 F-150: Replace The 0.4 Hr. ACM, Can Be Claimed Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-20-10 > Oct > 09 > Audio System - Inoperative/Speaker Popping Noise > Page 6786 with Operation B (Do Not Use With Any Labor Operation Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6792 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6793 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6799 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 09-22-13 > Nov > 09 > Brakes - Rear Brake Rattling Noise Over Bumps > Page 6800 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 6803 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 6804 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker, Left Front > Page 6805 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Door Speaker: Service and Repair Speaker - Door Speaker - Door NOTE: RH front shown, others similar. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Door > Page 6808 Speaker: Service and Repair Subwoofer Speaker Subwoofer Speaker - Explorer Sport Trac 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6814 Accessory Delay Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 6815 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: Customer Interest SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6828 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6829 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6834 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Customer Interest for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6835 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10-2-8 > Feb > 10 > SYNC(R) System - Defaults To 'Privacy Mode' Communications Control Module: All Technical Service Bulletins SYNC(R) System - Defaults To 'Privacy Mode' TSB 10-2-8 02/15/10 SYNC SYSTEM DEFAULTS TO OR STAYS IN PRIVACY MODE, MULTIPLE VEHICLE LINES FORD: 2008-2009 Taurus X 2008-2010 Focus, Fusion, Mustang, Taurus, Edge, Escape, Expedition, Explorer Sport Trac, Explorer, F-150, F-250, F-350, F-450 2009-2010 Flex LINCOLN: 2008-2010 MKZ 2009-2010 MKS 2008 Mark LT 2008-2010 MKX, Navigator 2010 MKT MERCURY: 2008-2009 Sable 2008-2010 Milan, Mariner, Mountaineer ISSUE Some customers of 2008-2010 SYNC-equipped vehicles may express concern with their SYNC paired device defaulting, switching or staying on privacy mode. The customer may not be able to accept the call through the SYNC system or must answer the call manually on their personal device. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Set the Privacy mode to Off on the device and recheck Sync operation. 2. If necessary, test the device on another vehicle with the same version SYNC. If the concern is still present, the device is the concern. Continue with normal WSM Diagnostics. NOTE PRIVACY MODE MEANS THAT THE PHONE IS CONTROLLING THE AUDIO. SYNC ONLY MAKES REQUESTS TO THE PHONE TO TRANSFER THIS RESPONSIBILITY OR AUDIO TO SYNC. IF THE PHONE DOES NOT ACCEPT THIS REQUEST OR THERE IS A PROBLEM IN THE COMMUNICATION TO MAKE THIS HAPPEN, YOU ARE BY DEFAULT IN PRIVACY MODE. WARRANTY STATUS: Information Only Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Communications Control Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6845 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6846 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Communications Control Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6851 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6852 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Locations > Accessory Protocol Interface Module (APIM) > Page 6855 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) Communications Control Module: Diagrams Accessory Protocol Interface Module (APIM) Part 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6858 Part 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6859 Communications Control Module: Diagrams Audio Control Module (ACM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6860 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Diagrams > Accessory Protocol Interface Module (APIM) > Page 6861 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures Communications Control Module: Procedures Accessory Protocol Interface Module (APIM) Software Level Check Accessory Protocol Interface Module (APIM) Software Level Check NOTE: This procedure applies to checking the Accessory Protocol Interface Module (APIM) software level. To program the APIM, refer to Accessory Protocol Interface Module (APIM) Programming in Information Bus. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection/Programming and Relearning/Accessory Protocol Interface Module (APIM) Programming 1. Turn the Audio Control Module (ACM) on. 2. Connect the scan tool to the Data Link Connector (DLC). 3. Connect one end of the Universal Serial Bus (USB) male-A to male-A cable to the scan tool. 4. Connect the other end of the USB male-A to male-A cable to the vehicle USB port. 5. From the technician service publication website, run On-Line Automotive Service Information System (OASIS) using Quick Start or by manually entering the Vehicle Identification Number (VIN). 6. From the OASIS tab, select the "Sync/APIM" bullet. 7. Select the "Read APIM" button to verify the current APIM software level. - The display shows both the Vehicle Interface Processor (VIP) and Consumer Interface Processor (CIP) software levels. 8. The scan tool displays the following information: - Last Recorded State - Hardware VIN: vehicle identification number associated with the current APIM - Installed date: date the APIM was installed - Radio: currently identified ACM in the vehicle - HW Part No.: APIM hardware part number - Un-installed date: date (if any) the APIM was uninstalled - S/N: APIM serial number - Last Recorded State - Software Date/Time: date and time of last recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6864 - Description: a description of the content of the software revision - History - Software Date/Time: date and time of any recorded software installation - VIP: VIP software that was installed at that time - CIP: CIP software that was installed at that time - Description: a description of the content of the software revision - Available Software for Programming Select: allows the software package to be selected - Lineage: the original software release, if the software available is a revision - VIP: VIP software level that is available with the selection - CIP: CIP software level that is available with the selection - Description: a description of the content of the software revision 9. Click a CIP software level to view the device compatibility list associated with the CIP software level, if desired. 10. To exit the APIM software level check, disconnect the scan tool from the DLC and the USB port, or exit the OASIS screen. Audio Control Module (ACM) Self-Diagnostic Mode Audio Control Module (ACM) Self-Diagnostic Mode Audio Systems Without Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after Step 3 by turning the ACM off. Before the speaker walk test is complete, carry out any of the following actions: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6865 5. To exit the self-diagnostic mode, turn the ACM off. Satellite Digital Audio Receiver System (SDARS) Module Electronic Serial Number (ESN) Retrieval - Vehicles Without Navigation 1. Operate the audio system in satellite radio mode. 2. Press and hold the AUX button and preset button 1, simultaneously. - The Satellite Digital Audio Receiver System (SDARS) module Electronic Serial Number (ESN) displays on the screen. 3. Record the SDARS module ESN. 4. Turn the audio system off. Audio Systems With Navigation 1. Turn the Audio Control Module (ACM) on. 2. Operate the audio system in radio tuner (AM/FM) mode. 3. Press and hold preset buttons 3 and 6 for 3 seconds until the speaker walk test begins. - The display indicates each speaker as it is tested. 4. NOTE: If the speaker walk test is the only test required, this procedure can be stopped after this step, or by allowing the speaker walk test to complete on its own. Before the speaker walk test is complete, press the "End Test" selection. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6866 5. The following tests are available through the "BEZEL DIAGNOSTICS" menu: 6. To exit the self-diagnostic mode, press the "Exit Diagnostics" selection from the "BEZEL DIAGNOSTICS" menu. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6867 Communications Control Module: Removal and Replacement Audio Control Module (ACM) Audio Control Module (ACM) Removal and Installation NOTE: It is not necessary to remove the Audio Control Module (ACM) to retrieve the part number. For additional information, refer to Audio Control Module (ACM) Self-Diagnostic Mode See: Procedures/Audio Control Module (ACM) Self-Diagnostic Mode. 1. NOTE: Module configuration is required when a new ACM is being installed. Upload the ACM configuration information to the scan tool. 2. Remove the instrument panel center finish panel. 3. Remove the 4 screws and the ACM. - Disconnect the ACM electrical connectors. 4. To install, reverse the removal procedure. - Download the configuration information to the ACM. Accessory Protocol Interface Module (APIM) Accessory Protocol Interface Module (APIM) Floor Console Components Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6868 Accessory Protocol Interface Module (APIM) Removal and Installation 1. NOTE: It is necessary to record the current Accessory Protocol Interface Module (APIM) software and hardware level when a new APIM is being installed to make sure that the new component is the same version as the component being replaced. Retrieve and record the current APIM software and hardware level. For additional information, refer to Accessory Protocol Interface Module (APIM) Software Level Check See: Procedures/Accessory Protocol Interface Module (APIM) Software Level Check. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6869 2. Remove the 4 screws and the front floor console stowage door. 3. Remove the 2 screws and the front floor console rear trim panel. - Pull straight back to disengage the clips. 4. Remove the 2 screws and the front floor console finish panel. - Pull straight up to disengage the clips. 5. Remove the front floor console stowage bin. - Remove the 4 screws. - Disconnect the audio input jack electrical connector. - Disconnect the Universal Serial Bus (USB) port electrical connector. - Disconnect the APIM electrical connector. - Disconnect the USB cable electrical connector (at the APIM). 6. Remove the 4 screws and the APIM. 7. To install, reverse the removal procedure. - If a new APIM is being installed, program the APIM to the correct software level. Universal Serial Bus (USB) Cable and Port Universal Serial Bus (USB) Cable and Port Floor Console Components Universal Serial Bus (USB) Cable And Port-To-Bezel Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6870 USB Cable And Port-To-Accessory Protocol Interface Module (APIM) Removal and Installation 1. Remove the 4 screws and the front floor console stowage door. 2. Remove the 2 screws and the front floor console rear trim panel. - Pull straight back to disengage the clips. 3. Remove the 2 screws and the front floor console finish panel. - Pull straight up to disengage the clips. 4. Using a suitable tool (such as a trim removal tool) pry the audio input jack bezel from the storage bin. - Disconnect the audio input jack electrical connector. 5. Disconnect the Universal Serial Bus (USB) port connector from the audio input jack bezel. 6. Remove the 4 screws and the front floor console stowage bin. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 6871 7. Remove the USB cable and port. - Disconnect the electrical connector. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: Customer Interest SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6880 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6881 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: Customer Interest SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6886 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6887 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6888 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6889 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6890 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6891 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6892 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6893 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6894 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6895 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6896 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Functions Inoperative/DTC's Set TSB 09-14-3 07/27/09 SYNC FUNCTIONS INOPERATIVE, DTC U3000-41, U0485, OR U0100, AND/OR BATTERY DRAW WITH ACCESSORY PROTOCOL INTERFACE MODULE CONNECTED FORD: 2008-2009 Focus, Taurus X, Taurus 2008-2010 Fusion 2010 Mustang 2008-2009 Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 Zephyr 2008-2010 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Sable 2008-2010 Milan 2008-2009 Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some 2008-2010 vehicles equipped with SYNC version 2 software level, SYNC 911 Assist and Vehicle Health Report, may exhibit all or most of the following symptoms: ^ Diagnostic Trouble Codes (DTC) U3000-41, U0485, or U0100 in Accessory Protocol Interface Module (APIM) ^ SYNC display menus/options blank ^ USB port inoperative ^ No SYNC Blue Tooth device connectivity ^ Voice/Phone/OK steering wheel controls inoperative ^ Lack of APIM communication ^ Parasitic battery draw with APIM connected These symptoms may be triggered by a low battery state of charge, or a recent battery disconnect/reconnect. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE This software upgrade only applies to the following Accessory Protocol Interface Module (APIM) Vehicle Interface Processor (VIP) and Customer Interface Processor (CIP) software levels: ^ VIP: 9L2T-14D205-AC / CIP: 9L2T-14D544-BC ^ VIP: 9L2T-14D205-AD / CIP: 9L2T-14D544-BD ^ VIP: 9L2T-14D205-AE / CIP: 9L2T-14D544-BD To determine the current APIM software level, reference the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6902 button and select the SYNC button. 1. Determine if communication can be established with the APIM using IDS. a. If communication cannot be verified, proceed to Step 2. b. If communication is present, proceed to Step 3. 2. Reference Workshop Manual, Section 418-00, Module Communication Network to determine if communication can be established. If not, perform an APIM power reset by disconnecting and reconnecting the vehicle battery. a. If communication is now present, proceed to Step 3. b. If communication still cannot be established, replace the APIM. 3. Reprogram the APIM to VIP software level 9L2T-14D205-AF by following the Service Procedure. NOTE SOFTWARE IS AVAILABLE ONLY THROUGH THE PTS WEBSITE, AND NOT AVAILABLE THROUGH THE SYNCMYRIDE.COM WEBSITE. NOTE CONFIGURATION AND PROGRAMMING REQUIRES THE USE OF A SPECIAL PTS APPLICATION. INSTALLER MUST HAVE ACCESS TO PTS AND HAVE A VALID PTS USER ID AND PASSWORD. a. Connect the vehicle communication module (VCM) to the data link connector (DLC). b. Connect the VCM to the IDS tool or laptop running IDS software. c. Turn the ignition key to the on position. d. Launch IDS tool. e. If required, update the VCM with the latest software. f. Close the IDS tool. g. From the PTS website, run OASIS by pressing the Read VIN And DTC's button. After vehicle communication is established, press the GO button. h. From the Vehicle Service Session screen, Select the SYNC button. i. Press read APIM button. j. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMU5B2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT USE A TRANSFER TYPE CABLE. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. k. Program the processor in the APIM. l. Connect the Male-A to Male-A USB cable, Rotunda part number CCMU5B2-AM-AM-10, to the IDS tool or laptop running IDS software, and to the vehicle USB port. m. Follow the on-screen instructions to program the VIP module. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-14-3 > Jul > 09 > SYNC(R) System - Functions Inoperative/DTC's Set > Page 6903 n. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. o. Exit PTS, disconnect the VCM and disconnect the USB cable. 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 MT091403 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - Poor Cell Phone Sound Quality TSB 09-13-5 07/13/09 SYNC - CALL SOUND QUALITY/BACKGROUND NOISE ISSUES AND/OR VOICE RECOGNITION DIFFICULTIES WHILE DRIVING FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner ISSUE Some customers of 2008-2009 SYNC equipped vehicles may express concern with their call sound quality while using the SYNC microphone, complaints of excessive background noise during a phone call, and/or issues with voice recognition accuracy while driving. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE The following service procedure involves updating the Accessory Protocol Interface Module (APIM) software level and installing an external alternate SYNC microphone attached to the headliner. NOTE THIS PROCEDURE DOES NOT APPLY TO DEALER-INSTALLED SYNC SYSTEMS. Do not perform Step 1 if vehicle is already equipped with SYNC 2.0 (911 and Vehicle Health Report) or has been upgraded to consumer interface processor (CIP) level 9L3T-14D544-AE. To determine the current APIM software level, Refer to the Professional Technician Society (PTS) website, enter the VIN in OASIS, click the GO button, and select the SYNC button. 1. Reprogram the APIM to CIP software level 9L3T-14D544-AE. For additional information Refer to other SYNC TSB's and WSM, Section 418-01. Service Pack files may also be obtained at www.syncmyride.com. When diagnosing a concern related to voice recognition (VR) difficulties, instruct the customer to test VR functionality while the vehicle is parked. If customer concerns are still present, this procedure will not yield an improvement, and the service procedure should not be performed. Instead, Refer to the SYNC supplement guide and www.syncmyride.com for additional VR tips to assist customer. The VR experience can be improved with user training and making improvements to the phone book entries (longer entries make the system more robust). Ensure the customer does not try to speak too loud or slow and remove any objects hanging on the rear view mirror as this will reduce system effectiveness. When diagnosing a concern related to call sound quality, expect marginal improvements for calls described as speaking in a tunnel, chamber, etc. Expect substantial improvements for complaints where the call audio seems to drop out intermittently. NOTE THIS REPAIR WILL CHANGE THE APPEARANCE OF THE VEHICLE INTERIOR. REFER TO THE PHOTOGRAPHS FOR THE APPLICABLE VEHICLE LOCATED IN THIS PROCEDURE. DO NOT PERFORM THIS REPAIR WITHOUT CUSTOMER APPROVAL PRIOR TO PROCEEDING WITH MICROPHONE INSTALLATION. 2. Install SYNC microphone service kit. Installing the kit includes mounting an external microphone directly to the headliner and splicing in a jumper harness to the vehicle's existing wiring harness. The existing SYNC microphone will no longer be functional. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6908 a. Refer to the appropriate vehicle line and microphone illustration(s) below for microphone installation and wire splicing locations. Refer to Wiring Diagram (WD), Section 5-1 for recommended splicing methods. b. Ensure the SYNC microphone wires are secure and do not interfere with vehicle operation or functionality. c. The microphone is directional. Make sure the microphone is always positioned so wire length is minimized from view. When installing the microphone adjacent to trim, place microphone as close to trim as possible to help minimize visible wire. 2008-2009 Edge / MKX 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 1) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connectors 210 and 211 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C211. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C210. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 Escape / Mariner Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6909 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figures 2 and 3). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 501-05 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 214 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C214. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD182 (BK-GY) from C214. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD1 82 (BK-GY). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Navigator / 2009 Expedition Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6910 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figures 4 and 5) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim (if equipped), or positioned directly above A-pillar on headliner if not equipped with an overhead console. ^ Proceed to Step 5 if not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 298 located behind the dash panel on passenger side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN07 (GY), RMN07 (VT), and DMN07 (shield - BK) from C298. Cut the three circuits on the male side of the connector (17C712 harness). 7. Identify circuits CBP31 (BU-OG) and GD133 (BK) from C298 (2008 Navigator only). Identify circuits CBP41 (BU) and GD133 (BK) from C298 (2009 Expedition/Navigator only). 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP31 (BU-OG) and any black jumper harness wire to GD133 (BK) for 2008 Navigator only. Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK) for 2009 Expedition/Navigator only. ^ Ensure original circuits remain connected in splice. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6911 ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2008-2009 Explorer / Explorer Sport Trac / Mountaineer 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 6) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 248 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify and cut circuits VMNO7 (GY), RMNO7 (VT), and DMNO7 (shield) from C248. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP05 (YE) and GD143 (BK-VT) from C248. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP05 (YE) and any black jumper harness wire to GD143 (BK-VT). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN07 (GY) and remaining black jumper harness wires to RMN07 (VT) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the cut wire ends heading up the A-pillar as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2009 F-150 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6912 1. Remove the protective backing from the adhesive on the microphone and attach the microphone. (Figure 7) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim or front lamp. 2. Lower the overhead console or front lamp. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and temporarily tuck excess wire into headliner to the rear of the console or lamp. 4. Install overhead console or front lamp; ensure microphone cable enters the overhead console or front lamp trim directly behind microphone as shown. 5. Gain access to connectors 314 and 315 in roof panel near left hand side. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C314. Cut the three circuits on the female side of the connector (14358 harness). 7. Identify circuits CBP41 (BU) from C315 and GD133 (BK) from C314. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the headliner. 2009 F-Super Duty Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6913 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 8) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. c. This repair is not recommended for vehicles not equipped with an overhead console. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 264 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield - BK) from C264. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C264. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield - BK). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Connect the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 Flex Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6914 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 9) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 925 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C925. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Focus Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6915 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration (Figure 10). Firmly press the microphone into place. Ensure the microphone is parallel and adjacent to the dome lamp trim. 2. Lower the dome lamp assembly. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable up through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install dome lamp assembly; ensure microphone cable enters the dome lamp trim directly behind microphone as shown. 5. Gain access to connector 934 in the right A-pillar. Refer to online WD for location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C934. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CPL60 (BN-YE) and GD161 (BK-YE) from C934. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CPL60 (BN-YE) and any black jumper harness wire to GD161 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable over the front of the headliner. 2008-2009 Fusion / Milan / MKZ Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6916 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 11) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the passenger side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 913 in the right A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMM13 (YE-GN), RMM13 (BU), and DMM13 (shield) from C913. Cut the three circuits on the female side of the connector (14334 harness). 7. Identify circuits CBP02 (GN) and GD139 (BK-YE) from C913. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP02 (GN) and any black jumper harness wire to GD139 (BK-YE). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMM13 (YE-GN) and remaining black jumper harness wires to RMM13 (BU) and DMM13 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2008-2009 Taurus / Sable / Taurus X 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 12) ^ Firmly press the microphone into place. ^ Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and over to the driver side A-pillar. It may be necessary to slightly drop headliner to run microphone cable. Refer to WSM, Section 501-05 for additional information. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6917 5. Gain access to connector 925 in the left A-pillar. Refer to online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMN02 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C925. Cut the three circuits on the female side of the connector (17K745 harness). 7. Identify circuits CBP41 (BU) and GD133 (BK) from C925. 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the cut wires heading in the direction of the connector. Tape off and secure the other cut wire ends as they are no longer used. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. 2009 MKS 1. Remove the protective backing from the adhesive on the microphone and attach the microphone as shown in the illustration. (Figure 13) a. Firmly press the microphone into place. b. Ensure the microphone is parallel and adjacent to overhead console trim. 2. Lower the overhead console. Refer to WSM, Section 417-02 for additional information. 3. Route microphone cable through existing hole in the headliner, and out the front of the headliner above the rear view mirror. 4. Install overhead console; ensure microphone cable enters the overhead console trim directly behind microphone as shown. 5. Gain access to connector 911 at the rear view mirror. Refer to the online WD, Section 124-1 for links to location and connector views. 6. Identify circuits VMNO2 (WH-BN), RMN02 (VT-BN), and DMN07 (shield) from C911. Pull back the black harness sleeve and cut the three circuits near C91 1 or if equipped with a headlamp control module-2 (HCM-2), remove the HCM-2 access cover and cut circuits under trim cover. Refer to WSM, Section 417-01 for additional information. 7. Identify circuits CBP41 (BU) and GD133 (BK) from C911. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-13-5 > Jul > 09 > SYNC(R) System - Poor Cell Phone Sound Quality > Page 6918 8. Splice the five jumper harness wires into the following circuits: ^ Blue jumper harness wire to CBP41 (BU) and any black jumper harness wire to GD133 (BK). ^ Ensure original circuits remain connected in splice. ^ Yellow jumper harness wire to VMN02 (WH-BN) and remaining black jumper harness wires to RMN02 (VT-BN) and DMN07 (shield). ^ Only splice into the wires heading away from the connector. The wires heading into the connector (mirror) are no longer used. ^ Ensure the wiring is neatly routed from the splice locations into the headliner, following the existing wire harness routing from mirror to headliner. 9. Attach the microphone connector to the jumper harness connector. 10. Bundle and tuck the remainder of the microphone cable above the front of the headliner. OTHER APPLICABLE ARTICLES: 08-21-2 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 MT091305 Claim Diagnosis And Labor Actual Performed As Actual Time. Time DEALER CODING CONDITION BASIC PART NO. CODE 17700 42 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6923 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6924 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade Emergency Contact Module: All Technical Service Bulletins SYNC(R) System - 911 Assist VHR Software Upgrade TSB 09-11-8 06/15/09 SYNC WITH 911 ASSIST AND VEHICLE HEALTH REPORT (VHR) DEALER UPGRADE SOFTWARE FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape Hybrid, Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner Hybrid, Mariner This article supersedes TSB 9-5-4 to update the Service Procedure and add a production fix date. ISSUE Some customers with 2008 or 2009 vehicles equipped with SYNC may request the 911 assist and vehicle health report (VHR) service upgrade installation. This software upgrade is not a warrantable repair. Software is available only through professional technician society (PTS) website, and not available through the syncmyride.com website. ACTION Follow the Service Procedure steps to upgrade the SYNC software. SERVICE PROCEDURE This software upgrade applies only to the following vehicle model years and build dates: ^ 2008-2009 Focus built before 1/20/2009 ^ 2008-2009 Explorer, Explorer Sport Trac, Mountaineer built before 1/12/2009 ^ 2008-2009 Edge, MKX, and 2009 Flex, Escape, Mariner built before 12/4/2008 ^ 2008-2009 Taurus, Taurus X, Sable, and 2009 F-Super Duty, MKS, F-150 built before 12/1/2008 ^ 2008-2009 Fusion, Milan, MKZ Vehicles built on or after these dates are already equipped with the 911 Assist/Vehicle Health Report features and do not require updating. To determine if the vehicles are within these build ranges or have already been upgraded to SYNC 911 Assist/VHR, access the Professional Technician Society (PTS) website, run OASIS by pressing the Read VIN and DTC's button, and click on the SYNC tab. If the description box indicates 911 and Vehicle Health Report, vehicle has been upgraded. The 911 assist with VHR upgrade automatically reprograms the accessory protocol interface module (APIM), instrument cluster (IC), and restraints control module (RCM). The VHR applies only to United States (US) vehicles, 911 assist is for US and Canadian vehicles operated within the US and Canada. Performing this upgrade may result in some untested devices losing certain functionality, such as bluetooth connection and phonebook download. Before continuing with this upgrade, make sure the customer's device is listed on the compatibility matrix. It is strongly recommended to pair the device to another vehicle currently equipped with 911 Assist/Vehicle Health Report to ensure proper functionality before continuing. Configuration and programming requires the use of IDS and a special PTS application. Installer must have access to PTS and have a valid PTS user ID and password. Ensure the IDS is at the latest software version. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6930 For additional programming tips, dealer network setting requirements, and possible error states related to 911 Assist and VHR upgrades, reference the latest information on the Professional Technician Society (PTS) website. 1. When updating 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles, it is necessary to manually record and reenter the Oil Life % Value as displayed on the message center. Record the current oil life before updating 911 Assist/VHR, and reenter using the message center once programming is complete. 2. Connect the vehicle communication module (VCM) to the data link connector (DLC). 3. Connect the VCM to the IDS tool or laptop running IDS software. 4. Turn the ignition key to the on position. 5. Launch IDS tool but do not start a new session. 6. If required, update the VCM with the latest IDS release 59.9 and higher. 7. Close the IDS tool. 8. From the P15 website, run OASIS by pressing the read VIN and DTC's button. After vehicle communication is established, press the go button. 9. From the Vehicle Service Session screen, select the Upgrade/Mods tab. 10. Once correct vehicle is chosen, select SYNC upgrade with 911 Assist/VHR. 11. Follow the on-screen instructions to program the APIM, IC, and RCM. NOTE TO COMPLETE THE UPGRADE PROCESS PERFORM THE FOLLOWING STEPS TO CONFIRM THE VEHICLE HAS BEEN CORRECTLY CONFIGURED TO HAVE THESE FEATURES. FAILING TO COMPLETE THE STEPS BELOW MAY RESULT IN 911 ASSIST/VHR NOT DISPLAYING ON THE SYNC MENU. 12. Set ignition to off. 13. Open and close driver side door. 14. Set ignition to on. 15. Follow applicable instructions (see below) to ensure 911 Assist/VHR appear on Sync menu. 16. Close all Internet Explorer browser windows. 17. Clear all DTC's on all modules. 18. Reenter the Oil Life % Value for 2008-2009 Explorer, Mountaineer, Explorer Sport Trac, Expedition, or Navigator vehicles. Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on the Navigation LCD to enter phone menu. 2. Press cancel when pop-up menu appears on Navigation LCD display. 3. Press settings soft key on Navigation LCD display. 4. Press advanced soft key on Navigation LCD display. 5. Verify 911 Assist/VHR is in menu in Navigation LCD display. Non Navigation Radio Instructions 911 Assist/VHR feature confirmation. 1. Press phone button on steering wheel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-11-8 > Jun > 09 > SYNC(R) System - 911 Assist VHR Software Upgrade > Page 6931 2. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 3. Press left arrow on steering wheel until return is displayed on radio screen, then press ok. 4. Press left arrow until 911 Assist/VHR is displayed. Once 911 Assist/VHR installation is complete, the customer will need to reload their phone book if that application is desired. NOTE IF SERVICE IS REQUIRED ON 2008 OR 2009 EARLY BUILT VEHICLES UPGRADED TO 911 ASSIST/VHR, REFERENCE THE APPLICABLE 2009 WORKSHOP MANUAL AND FOLLOW THE V2 DIAGNOSTIC PROCEDURES. WARRANTY STATUS: Information Only - Not Warrantable Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Customer Interest for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: Customer Interest Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Entertainment System Control Module: > 10-9-7 > May > 10 > Audio System - Unexpected CD Shuffle With Key Off Entertainment System Control Module: All Technical Service Bulletins Audio System - Unexpected CD Shuffle With Key Off TSB 10-9-7 05/24/10 UNEXPECTED COMPACT DISC SHUFFLE OR CYCLING DURING NORMAL RADIO OPERATION OR WITH THE KEY OFF - NON-NAVIGATION RADIOS ONLY FORD: 2008-2010 Expedition, Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Expedition, Explorer, Explorer Sport Trac and Mountaineer vehicles equipped with a non-navigation CD-6 Audio Control Module (ACM) may experience an unexpected Compact Disc (CD) shuffle or cycling during start up, during normal ACM operation, or shutting off the vehicle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE This service procedure affects non-navigation radios only. If you attempt to run module reprogramming on the 2008-2010 ACM and the service tool does not recognize the part numbers of the ACM currently installed, this procedure does not apply. Reprogram the ACM to the latest calibration using IDS release 66.05A and higher. This new calibration is not included in the VCM 2010. Version A 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 100907A 2008-2010 Expedition, 0.3 Hr. Explorer, Mountaineer, And Explorer Sport Trac: Reprogram The Audio Control Module (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE RECAL 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 6945 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Technical Service Bulletins > Page 6946 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6955 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > Customer Interest for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6956 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Global Positioning System Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6962 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6963 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: Customer Interest SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6972 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > Customer Interest for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6973 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns Navigation Module: All Technical Service Bulletins SYNC(R) System - Software Update For Various Concerns TSB 09-26-8 01/04/10 SYNC SOFTWARE UPDATE - VARIOUS ISSUES FORD: 2008-2009 Focus, Fusion, Taurus X, Taurus, Edge, Explorer Sport Trac, Explorer 2009 Escape, Expedition, F-150, F-Super Duty, Flex LINCOLN: 2008-2009 MKZ 2009 MKS 2008-2009 MKX, Navigator MERCURY: 2008-2009 Milan, Sable, Mountaineer 2009 Mariner This article supersedes TSB 9-22-14 to update the Service Procedure. ISSUE Some 2008 and 2009 SYNC® equipped vehicles may exhibit one or more of the following symptoms: ^ Universal Serial Bus (USB) port inoperative. ^ USB audio muting when using various non-Apple USB devices. ^ Phone book access difficulty on certain 2-digit phone book entries when using voice commands. ^ Excessive background noise and/or poor voice sound quality. ^ Phone book auto download inoperative on supported devices. ^ SYNC steering wheel control (SWC) switches being inoperative intermittently. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Reprogram the accessory protocol inter[ace module (APIM) to the following consumer inter[ace processor (CIP) software levels. ^ 9L3T-14D544-AE (vehicles not equipped with SYNC V2, 911 Assist and Vehicle Health Report) ^ 9L2T-14D544-BE (vehicles already equipped with SYNC V2, 911 Assist and Vehicle Health Report) Service Pack files may be obtained at www.syncmyride.com. Reprogram the APIM Contains software fix updates for the following: ^ Phone book auto download inoperative. ^ USB audio muting. ^ SYNC steering wheel control (SWC) switches being inoperative. ^ Voice recognition on 2-digit entries. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6979 ^ USB port inoperative with diagnostic trouble code (DTC) B1342. ^ Poor call sound quality. This software update also contains enhancements that will improve the reliability of both Bluetooth and USB connections to SYNC(R) from various consumer devices, and microphone enhancements to reduce background noise, and will default Vehicle Health Report (if equipped) to off. The Bluetooth enhancements improve the stability of hands-free calls, call waiting, caller ID, multiple call handling and other mobile phone features. The USB enhancements improve support for media players and the playing of file formats and podcasts. NOTE REFERENCE OTHER TECHNICAL SERVICE BULLETINS (TSB) FOR ADDITIONAL SYNC SOFTWARE PROGRAMMING TIPS. 1. Connect the vehicle communication module (VCM) to the data link connector (DLC). 2. Connect the VCM to the Integrated Diagnostic System (IDS) tool or laptop running IDS software. 3. Turn the ignition key to the on position. 4. Launch IDS tool. 5. If required, update the VCM with the latest software. 6. Close the IDS tool. 7. From the PTS website, run OASIS by pressing the Read VIN & DTC's button. After vehicle communication is established, press the GO button. 8. From the Vehicle Service Session screen, Select the SYNC button. 9. Press read APIM button. 10. Select software and press program APIM to update the SYNC module. NOTE YOU MUST USE A MALE-A TO MALE-A USB CABLE LIKE ROTUNDA PART NUMBER CCMUSB2-AM-AM-10 TO COMPLETE THIS STEP. NOTE DO NOT DISCONNECT THE VCM OR USB CABLES DURING APIM PROGRAMMING. NOTE THE SYSTEM MAY PROMPT YOU TO INSTALL SOFTWARE FOR THE USB PORT. FOLLOW THE ON SCREEN INSTRUCTIONS TO INSTALL THE USB PORT DRIVER ALREADY INCLUDED IN WINDOWS XP. 11. Program both processors in the APIM (Vehicle Interface Processor (VIP) and CIP). NOTE DO NOT USE A MALE-TO-MALE USB DATA TRANSFER TYPE CABLE. a. Connect the Male-A to Male-A USB cable, Rotunda part number CCMUSB2-AM-AM-10, to the IDS tool or laptop running IDS software and to the vehicle USB port. b. Follow the on-screen instructions to program both processors on the Sync module (VIP and CIP). 12. At the end of the configuration and programming procedure, the programming has been completed successfully screen will be displayed. 13. Exit PTS, disconnect the VCM and disconnect the USB cable. OTHER APPLICABLE ARTICLES: 08-21-02 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 092608A 2008-2009 Edge, Explorer, 0.4 Hr. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Navigation Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation Module: > 09-26-8 > Jan > 10 > SYNC(R) System - Software Update For Various Concerns > Page 6980 Mountaineer, Explorer Sport Trac, Focus, Fusion, Milan, MKX, MKZ, Sable, Navigator, Taurus, Taurus X, 2009 Expedition, Escape, Escape Hybrid, Mariner, Mariner Hybrid, F-150, F-Super Duty, Flex, MKS: Reprogram The APIM (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 14D212 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Parking Assist Control Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6984 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6985 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6986 Parking Assist Control Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6987 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6988 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 6989 Parking Assist Control Module: Service and Repair Parking Aid Module (PAM) - Explorer Sport Trac Removal and Installation 1. Remove the cab rear trim panel. 2. If replacing the parking aid speaker only, proceed as follows: - Disconnect the parking aid speaker electrical connector. - Disengage the parking aid speaker clips. - Remove the parking aid speaker. 3. If replacing the Parking Aid Module (PAM), proceed as follows: - Disconnect the electrical connectors. - Remove the PAM screw. - Remove the PAM. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6995 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6996 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6997 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6998 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 6999 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 7000 Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 7001 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7004 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7005 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7006 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 7007 Parking Assist Distance Sensor: Service and Repair Parking Aid Sensor - Mountaineer, Explorer Sport Trac NOTE: Mountaineer shown, Explorer Sport Trac similar. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 7011 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7015 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Locations > Page 7020 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 Trailer Connector: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7045 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7046 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7047 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 rear 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7051 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7052 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7053 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7054 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7055 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7056 SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER All vehicles 8. Deburr 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 or pull together the frame rails slightly to get the brackets to fit. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7057 Insert the new trailer hitch crossmember 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 (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7079 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Special Tools Used With Diagnostics Trailer Lamps Principles Of Operation Trailer Lamps Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The SJB uses existing inputs to determine if voltage needs to be supplied to the individual trailer stop/turn lamps. The SJB has separate drivers that provide voltage for the trailer stop/turn lamps. The trailer parking and reversing lamps share the vehicle lighting outputs. The vehicle is supplied with wiring to support an aftermarket . The trailer tow battery charging is controlled by a relay. When the ignition switch is in the RUN or ACC position, the trailer tow battery charge relay is energized, which routes voltage to the trailer tow connector. Field-Effect Transistor (FET) Protection The SJB utilizes a Field-Effect Transistor (FET) protective circuit strategy for many of its outputs (for example, a headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault event is detected. A continuous DTC is stored at the fault event and a cumulative counter is started. When the demand for the output is no longer present, the module resets the FET circuit protection to allow the circuit to function. The next time the driver requests a circuit to activate that has been shut down by a previous short (FET protection) and the circuit remains shorted, the FET protection shuts off the circuit again and the cumulative counter advances. When the excessive circuit load occurs often enough, the module shuts down the output until a repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to withstand it. A module lifetime level of fault events is established based upon the durability of the FET. If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would be 200, 400 and 600 fault events. When each tolerance level is reached, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal operation until a successful self-test proves that the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs present), the continuous DTC automatically clears and the circuit function returns. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7085 When the first or second level is reached, the continuous DTC (associated with the short circuit) sets along with DTC B106E. These DTCs can be cleared using the module on-demand self-test, then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected). The module never resets the fault event counter to zero and continues to advance the fault event counter as short circuit fault events occur. If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set along with the associated continuous DTC. This DTC cannot be cleared and the module must be replaced. The SJB FET protected output circuits for the trailer lamp system are the LH and RH trailer stop/turn output circuits. Inspection And Verification Trailer Lamps 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 for obvious signs of electrical damage. Visual Inspection Chart 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. NOTE: Make sure the multifunction switch is in the LOW BEAM position. 5. 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). 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, No Power To The Scan Tool, to diagnose no power to 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 to diagnose no response from the PCM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7086 8. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus. - 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 Diagnostic Trouble Code (DTC) Chart See: Lighting and Horns/Testing and Inspection. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart 11. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7087 Trailer Lamps: Symptom Related Diagnostic Procedures Trailer Lamps Symptom Chart Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7088 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7089 Trailer Lamps: Pinpoint Tests Pinpoint Test W: All The Trailer Lamps Are Inoperative Trailer Lamps Pinpoint Tests Pinpoint Test W: All the Trailer Lamps Are Inoperative Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Ground for all the trailer lamps is provided through circuit RAT08 (WH). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - Trailer PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- W1 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN TO THE TRAILER TOW CONNECTOR - Disconnect the trailer from the vehicle. - Disconnect: Negative Battery Cable. - For the 4-pin connector, measure the resistance between the trailer tow C439-4, circuit RAT08 (WH), harness side and ground. - For the 7-pin connector, measure the resistance between the trailer tow connector pin 2, circuit RAT08 (WH), component side and ground. - Is the resistance less than 5 ohms? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7090 For the 4-pin connector, REPAIR the circuit. TEST the system for normal operation. For the 7-pin connector, GO to W2. ------------------------------------------------- W2 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN - Disconnect: Trailer Tow C473. - Measure the resistance between the trailer tow C473-2, circuit RAT08 (WH), harness side and ground. - Is the resistance less than 5 ohms? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps Trailer Lamps Pinpoint Tests Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation When the vehicle parking lamps are on, the Smart Junction Box (SJB) provides voltage to the trailer parking lamps through circuit CAT17 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING LAMPS NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- X1 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - Place the headlamp switch in the PARKING LAMPS ON position. - For the 4-pin connector, measure the voltage between the trailer tow C439-3, circuit CAT17 (BN), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7091 - For the 7-pin connector, measure the voltage between the trailer tow connector pin 6, circuit CAT17 (BN), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No VERIFY the SJB fuse 25 (15A) is OK. If OK for the 4-pin connector, GO to X3. If OK for the 7-pin connector, GO to X2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- X2 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C473. - Measure the voltage between the trailer tow C473-6, circuit CAT17 (BN), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to X3. ------------------------------------------------- X3 CHECK CIRCUIT CAT17 (BN) FOR AN OPEN - Place the headlamp switch in the OFF position. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-13, circuit CAT17 (BN), harness side and the trailer tow C439-3 (4-pin connector) or C473-6 (7-pin connector), circuit CAT17 (BN), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7092 - Is the resistance less than 5 ohms? Yes GO to X4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- X4 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps Trailer Lamps Pinpoint Tests Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Voltage to the trailer reversing lamps is supplied by the Smart Junction Box (SJB) through circuit CAT16 (GY/BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7093 connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- Y1 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - Apply the parking brake. - Ignition ON. - Select REVERSE. - Measure the voltage between the trailer tow connector pin 7, circuit CAT16 (GY/BN), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No VERIFY the SJB fuse 16 (10A) is OK. If OK, GO to Y2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- Y2 CHECK FOR VOLTAGE ON CIRCUIT CAT16 (GY/BN) - Disconnect: Trailer Tow C473. - Measure the voltage between the trailer tow C473-7, circuit CAT16 (GY/BN), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to Y3. ------------------------------------------------- Y3 CHECK CIRCUIT CAT16 (GY/BN) FOR AN OPEN - Select PARK. - Ignition OFF. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-21, circuit CAT16 (GY/BN), harness side and the trailer tow C473-7, circuit CAT16 (GY/BN), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7094 - Is the resistance less than 5 ohms? Yes GO to Y4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- Y4 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp Trailer Lamps Pinpoint Tests Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Voltage to the LH trailer stop/turn lamp is supplied by the Smart Junction Box (SJB) through circuit CAT06 (YE). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - a continuous DTC that sets when the SJB detects a short to ground from the LH trailer stop/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 trailer stop/turn lamp voltage supply. A trailer equipped with too many LH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7095 PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- Z1 CHECK THE RECORDED DTCs FROM THE SJB SELF-TEST - Check the recorded results from the SJB self-test. - Was DTC B2070 present? Yes GO to Z2. No GO to Z6. ------------------------------------------------- Z2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND SELF-TEST WITH THE TRAILER DISCONNECTED - Disconnect the trailer from the vehicle. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Yes For the 4-pin connector, GO to Z5. For the 7-pin connector, GO to Z4. No GO to Z3. ------------------------------------------------- Z3 CHECK THE NUMBER OF BULBS ON THE TRAILER - Inspect the trailer for more than 2 LH stop/turn lamp bulbs. - Are more than 2 LH stop/turn lamp bulbs present? Yes INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for the trailer tow lamps to operate correctly. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- Z4 CHECK THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C473. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7096 GO to Z5. No INSTALL a new trailer tow connector. TEST the system for normal operation. ------------------------------------------------- Z5 CHECK CIRCUIT CAT06 (YE) FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to Z9. No REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. ------------------------------------------------- Z6 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Disconnect the trailer from the vehicle. - Ignition OFF. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C439-2, circuit CAT06 (YE), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow connector pin 1, circuit CAT06 (YE), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. TEST the system for normal operation. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7097 For the 4-pin connector, GO to Z8. For the 7-pin connector, GO to Z7. ------------------------------------------------- Z7 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C473. - While applying the brake pedal, measure the voltage between the trailer tow C473-1, circuit CAT06 (YE), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to Z8. ------------------------------------------------- Z8 CHECK CIRCUIT CAT06 (YE) FOR AN OPEN - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and the trailer tow C439-2 (4-pin) or C473-1 (7-pin), circuit CAT06 (YE), harness side. - Is the resistance less than 5 ohms? Yes GO to Z9. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- Z9 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7098 INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp Trailer Lamps Pinpoint Tests Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Voltage to the RH trailer stop/turn lamp is supplied by the Smart Junction Box (SJB) through circuit CAT09 (GN). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - a continuous DTC that sets when the SJB detects a short to ground from the RH trailer stop/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 trailer stop/turn lamp voltage supply. A trailer equipped with too many RH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN LAMP NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- AA1 CHECK THE RECORDED DTCs FROM THE SJB SELF-TEST - Check the recorded results from the SJB self-test. - Was DTC B2070 present? Yes GO to AA2. No GO to AA6. ------------------------------------------------- AA2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND SELF-TEST WITH THE TRAILER DISCONNECTED - Disconnect the trailer from the vehicle. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7099 Yes For the 4-pin connector, GO to AA5. For the 7-pin connector, GO to AA4. No GO to AA3. ------------------------------------------------- AA3 CHECK THE NUMBER OF BULBS ON THE TRAILER - Inspect the trailer for more than 2 RH stop/turn lamp bulbs. - Are more than 2 RH stop/turn lamp bulbs present? Yes INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for the trailer tow lamps to operate correctly. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AA4 CHECK THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow 473. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Yes GO to AA5. No INSTALL a new trailer tow connector. TEST the system for normal operation. ------------------------------------------------- AA5 CHECK CIRCUIT CAT09 (GN) FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to AA9. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7100 REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. ------------------------------------------------- AA6 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C439-1, circuit CAT09 (GN), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow connector pin 4, circuit CAT09 (GN), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. TEST the system for normal operation. No For the 4-pin connector, GO to AA8. For the 7-pin connector, GO to AA7. ------------------------------------------------- AA7 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C473. - While applying the brake pedal, measure the voltage between the trailer tow C473-4, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to AA8. ------------------------------------------------- AA8 CHECK CIRCUIT CAT09 (GN) FOR AN OPEN Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7101 - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and the trailer tow C439-1 (4-pin) or C473-4 (7-pin), circuit CAT09 (GN), harness side. - Is the resistance less than 5 ohms? Yes GO to AA9. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- AA9 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are On Continuously Trailer Lamps Pinpoint Tests Pinpoint Test AB: The Trailer Lamps Are On Continuously Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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. The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps. This pinpoint test is intended to diagnose the following: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7102 - Wiring, terminals or connectors - Trailer - SJB PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- AB1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - Ignition ON. - Measure the voltage between the trailer tow connector, harness side and ground as follows: - Is any voltage present? Yes GO to AB2. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AB2 CHECK THE SJB - Ignition OFF. - Disconnect: SJB C2280a. - Ignition ON. - Measure the voltage between the trailer tow connector, harness side and ground as follows: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7103 - Is any voltage present? Yes REPAIR the circuit in question. TEST the system for normal operation. No GO to AB3. ------------------------------------------------- AB3 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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 switch 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). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer battery charge relay - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7104 PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- AC1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTION (BATTERY CHARGE INOPERATIVE) - Ignition OFF. - Disconnect the trailer from the vehicle. - Ignition ON. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. Is the voltage greater than 10 volts? Yes GO to AC8. No VERIFY the BJB fuse 13 (30A) is OK. If OK, GO to AC2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AC2 CHECK THE TRAILER BATTERY CHARGE RELAY (INOPERATIVE) - Ignition OFF. - Disconnect: Trailer Battery Charge Relay. - Substitute the trailer battery charge relay with a known good relay. - Ignition ON. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer battery charge relay. TEST the system for normal operation. No REMOVE the known good relay. INSTALL the original relay. GO to AC3. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7105 AC3 CHECK THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect: Trailer Tow C473. - Ignition ON. - Measure the voltage between the trailer tow C473-5, circuit CAT14 (OG) and ground. Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to AC4. ------------------------------------------------- AC4 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY COIL - Ignition OFF. - Disconnect: Trailer Battery Charge Relay. - Ignition ON. - Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AC6. No VERIFY the SJB fuse 12 (5A) is OK. If OK, GO to AC5. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AC5 CHECK CIRCUIT CBP12 (GN/WH) FOR AN OPEN - Ignition OFF. - Disconnect: SJB C2280e. - Measure the resistance between trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB face side and the SJB C2280e-6, circuit CBP12 (GN/WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7106 - Is the resistance less than 5 ohms? Yes GO to AC12. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- AC6 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer battery charge relay pin 85, circuit GD120 (BK/GN), BJB face side and ground. - Is the resistance less than 5 ohms? Yes GO to AC7. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- AC7 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY - Measure the voltage between the trailer battery charge relay pin 30, circuit SSB13 (GY/RD), BJB face side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7107 - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT14 (OG) for an open. TEST the system for normal operation. No REPAIR circuit SSB13 (GY/RD) for an open. TEST the system for normal operation. ------------------------------------------------- AC8 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR (BATTERY CHARGE ALWAYS ON) - Ignition OFF. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. - Is any voltage present? Yes GO to AC9. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AC9 CHECK CIRCUIT CAT14 (OG) FOR A SHORT TO VOLTAGE - Disconnect: Trailer Battery Charge Relay. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7108 - Is any voltage present? Yes REPAIR the circuit. TEST the system for normal operation. No GO to AC10. ------------------------------------------------- AC10 CHECK THE TRAILER BATTERY CHARGE RELAY (ALWAYS ON) - Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB face side and ground. - Is any voltage present? Yes GO to AC11. No INSTALL a new trailer battery charge relay. TEST the system for normal operation. ------------------------------------------------- AC11 CHECK CIRCUIT CBP12 (GN/WH) FOR A SHORT TO VOLTAGE - Disconnect: SJB C2280e. - Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7109 Is any voltage present? Yes REPAIR the circuit. TEST the system for normal operation. No GO to AC12. ------------------------------------------------- AC12 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The is provided voltage at all times by the Battery Junction Box (BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the TBC module is provided through circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested, the TBC module provides voltage to the trailer tow connector through circuit CAT19 (BU). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7110 This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TBC module - Trailer tow connector - Trailer PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- AD1 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (INOPERATIVE CONDITION) - Ignition OFF. - Disconnect the trailer from the vehicle. - While applying the brake pedal, measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. - Is the voltage greater than 10 volts? Yes GO to AD8. No GO to AD2. ------------------------------------------------- AD2 CHECK THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C473. - While applying the brake pedal, measure the voltage between the trailer tow C473-3, circuit CAT19 (BU), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to AD3. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7111 ------------------------------------------------- AD3 CHECK CIRCUIT SBB17 (RD) FOR AN OPEN - Disconnect: C238. - Measure the voltage between the TBC module C238-1, circuit SBB17 (RD), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7112 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 7116 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 7117 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 7121 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations > Page 7122 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 Trailer Connector: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 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 (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications Body Control Systems: Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > Specifications > Page 7154 Body Control Systems: Description and Operation Module Controlled Functions NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The 2 multifunction electronic modules on this vehicle are the: - Driver Seat Module (DSM) - Smart Junction Box (SJB) Driver Seat Module (DSM) The Driver Seat Module (DSM) is located under the driver seat. The DSM controls the memory functions of the memory seat positions and the adjustable pedals. The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or the Remote Keyless Entry (RKE) transmitter. Refer to Locks. Smart Junction Box (SJB) The SJB (located under the instrument panel on the driver side) is a combination of a multifunction electronic module and an interior junction box. The SJB functions control multiple systems, which include: - Accessory delay - Battery saver - Exterior lighting - Heated rear window and mirrors - Horn - Illuminated entry and interior lighting - Power door locks - RKE system/keyless entry keypad - Tire Pressure Monitoring System (TPMS) - Warning chimes - Windshield wiper Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview Body Control Systems: Initial Inspection and Diagnostic Overview Inspection And Verification Driver Seat Module (DSM) Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 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, No Power To The Scan Tool, to diagnose no power to 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 to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus. - 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 DSM. 9. If the DTCs retrieved are related to the concern, refer to Diagnostic Trouble Code (DTC) Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures/Driver Seat Module (DSM) Principles Of Operation Driver Seat Module (DSM) Principles of Operation The Driver Seat Module (DSM) controls the memory driver seat positions and the memory adjustable pedals. The DSM receives inputs from the memory set switches in order to program the 2 separate, personalized memory positions for the seats and (if equipped) the adjustable pedals. These Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7157 positions can be recalled by either pressing the memory switches or by unlocking the vehicle with the remote transmitters. The DSM also receives inputs from the driver seat switch and outputs the requested command to the seats. If the vehicle has memory, the DSM will also receive inputs from the adjustable pedal switch and outputs the requested commands to the adjustable pedal motor. The memory driver seat feature allows the driver to program a personalized seat position that can be recalled using the memory switches or the Remote Keyless Entry (RKE) transmitter. Refer to Locks for the remote memory activation general procedure. The DSM is on the Medium Speed Controller Area Network (MS-CAN). The DSM supports inter-module and scan tool communications. Special Tools Used With Diagnostics Driver Seat Module (DSM) Inspection And Verification Smart Junction Box (SJB) Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7158 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, No Power To The Scan Tool, to diagnose no power to 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 to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus. - 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, refer to Diagnostic Trouble Code (DTC) Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. 10. If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures/Smart Junction Box (SJB) Principles Of Operation Smart Junction Box (SJB) Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The SJB receives inputs and delivers outputs to electronically-controlled features of the vehicle. The SJB constantly monitors the systems under its control and reports a concern in the form of a DTC. The DTC can be retrieved with a scan tool through the Medium Speed Controller Area Network (MS-CAN). Special Tools Used With Diagnostics Smart Junction Box (SJB) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7159 Body Control Systems: Diagnostic Trouble Code Descriptions Diagnostic Trouble Code (DTC) Chart Diagnostic Trouble Code (DTC) Chart NOTE: Most powertrain (P-code) DTCs are diagnosed in Computers and Control Systems Information. If the P-code retrieved is not listed below, refer to Computers and Control Systems Information to continue diagnostics. NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). NOTE: Some of these modules utilize a 5-character DTC followed by a 2-character failure-type code. The failure-type code provides information about specific fault conditions such as opens, or shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in determining DTC history. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7160 B106A-B1171 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7161 B11BA:1C-B1259 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7162 B1261-B1342 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7163 B1342-B1571 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7164 B1578-B1884 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7165 B1A01:01-B2027 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7166 B229A-B2296 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7167 B229B-B2607 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7168 B287A-B2986 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7169 B2987 / C1095-C1703 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7170 C1704-C2780 / P0218 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7171 P062F-P0716 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7172 P0717-P0755 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7173 P0758-P0973 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7174 P0974-P1716 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7175 PXXXX-P2764 / U0073-U0100 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7176 U0100:00-U0193 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7177 U0196-U2013 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7178 U201A:51-U2051 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7179 U261A-U3003:17 Driver Seat Module (DSM) DTC Chart Driver Seat Module (DSM) DTC Charts B1317-B2143 Smart Junction Box (SJB) DTC Chart Smart Junction Box (SJB) DTC Charts Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7180 B106E-B2141 / U0155-U0164 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7181 Body Control Systems: Symptom Related Diagnostic Procedures Driver Seat Module (DSM) Driver Seat Module (DSM) Symptom Chart Symptom Chart Smart Junction Box (SJB) Smart Junction Box (SJB) Symptom Chart Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7182 Body Control Systems: Pinpoint Tests Pinpoint Test F: DTC B1317 Driver Seat Module (DSM) Pinpoint Tests Pinpoint Test F: DTC B1317 Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Driver Seat Module (DSM) monitors the voltage from the battery to determine if it goes above or below specific thresholds and sets DTC B1317 in continuous memory if the DSM detects high battery voltage above 15 volts on circuit SBB14 (BN/RD). - DTC B1317 (Battery Voltage High) - a continuous memory DTC that sets when the DSM detects battery voltage above 15 volts on circuit SBB14 (BN/RD). This pinpoint test is intended to diagnose the following: - Charging system concern - DSM PINPOINT TEST F: DTC B1317 NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump starting events. ------------------------------------------------- F1 CHECK FOR DTCs B1317, B1676 OR P0563 SET IN OTHER MODULES - Ignition ON. - Enter the following diagnostic mode on the scan tool: (All Modules) Self-Test. - Retrieve the continuous memory DTCs from all modules. - Is DTC B1317, B1676 or P0563 (PCM) set in more than one module? Yes REFER to Charging System to diagnose an overcharging condition. No GO to F2. ------------------------------------------------- F2 CHECK THE BATTERY VOLTAGE - Turn off all interior/exterior lights and accessories. - Start and run the engine at approximately 2,000 rpm for 3 minutes while monitoring the battery voltage. - Does the battery voltage rise to 15 volts or higher? Yes REFER to Charging System to diagnose an overcharging condition. No GO to F3. ------------------------------------------------- F3 RECHECK FOR DTC B1317 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7183 - Turn the engine off. - Ignition ON. - Enter the following diagnostic mode on the scan tool: DSM Self-Test. - Clear the continuous memory DTCs. - Carry out the DSM self-test. - Is DTC B1317 present? Yes INSTALL a new DSM. REFER to Driver Seat Module (DSM) See: Mirrors/Memory Positioning Systems/Memory Positioning Module/Service and Repair. TEST the system for normal operation. No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump starting the vehicle. ------------------------------------------------Pinpoint Test G: DTC B1318 Driver Seat Module (DSM) Pinpoint Tests Pinpoint Test G: DTC B1318 Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Driver Seat Module (DSM) monitors the voltage from the battery to determine if it goes above or below specific thresholds and sets DTC B1318 in continuous memory if the DSM detects low battery voltage below 10 volts on circuit SBB14 (BN/RD). - DTC B1318 (Battery Voltage Low) - a continuous memory DTC that sets when the DSM detects battery voltage below 10 volts on circuit SBB14 (BN/RD). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - High circuit resistance - DSM PINPOINT TEST G: DTC B1318 NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- G1 RECHECK THE DSM DTCs - Ignition ON. - Enter the following diagnostic mode on the scan tool: DSM Self-Test. - Clear the DTCs. Repeat the DSM self-test. - Is DTC B1318 still present? Yes GO to G2. No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump starting the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7184 ------------------------------------------------- G2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM - Enter the following diagnostic mode on the scan tool: PCM Self-Test. - Retrieve the continuous memory DTCs from the PCM. - Is DTC P0620, P0625, P0626 or P065B set in the PCM? Yes REFER to Charging System. No GO to G3. ------------------------------------------------- G3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE - Ignition OFF. - Check the battery condition and verify the battery is fully charged. Refer to Battery, Battery Condition Test. See: Starting and Charging/Battery/Testing and Inspection/Pinpoint Tests - Is the battery OK and fully charged? Yes GO to G4. No REFER to Charging System. ------------------------------------------------- G4 CHECK THE DSM VOLTAGE SUPPLY - Measure and record the voltage at the battery. - Disconnect: DSM C341A. - Ignition ON. - Measure the voltage between the DSM C341A-2, circuit SBB14 (BN/RD), harness side and ground. - Is the voltage within 0.2 volt of the recorded battery voltage? Yes GO to G5. No REPAIR the circuit for high resistance. CLEAR the DTC. REPEAT the self-test. ------------------------------------------------- G5 CHECK THE DSM GROUND CIRCUIT - Ignition OFF. - Disconnect: Negative Battery Cable. - Disconnect: DSM C341C. - Measure the resistance between the DSM C341C-13, circuit GD143 (BK/VT), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7185 - Is the resistance less than 5 ohms? Yes CONNECT the negative battery cable. GO to G6. No REPAIR the circuit for high resistance. CONNECT the negative battery cable. TEST the system for normal operation. ------------------------------------------------- G6 CHECK FOR CORRECT DSM OPERATION - Disconnect the DSM connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect the DSM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. Is the concern still present? Yes INSTALL a new DSM. REFER to Driver Seat Module (DSM) See: Mirrors/Memory Positioning Systems/Memory Positioning Module/Service and Repair. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test A: DTC B106E/B106F Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test A: DTC B106E/B106F Normal Operation The Smart Junction Box (SJB) controls the output of the Daytime Running Lamps (DRL), fog lamps, one-touch down driver power window, accessory delay relay, windshield wiper park/run, windshield wiper speed, and windshield washer. When a repetitive fault causing a circuit overload is detected on any of the output circuits, the SJB disables the circuit by removing voltage, or ground, to the affected circuit. The circuit remains disabled until the fault is corrected and an on-demand self-test is run. After the on-demand self-test has been run, any DTCs related to the fault will be cleared. - DTC B106E (Module Output Pin Disabled To Protect From External Fault) - sets when the SJB has temporarily disabled a circuit due to a repetitive fault causing a circuit overload. A corresponding DTC for the circuit in question will also set as follows: DTC B106F (Module Disabled Due to External Fault) - sets when one or more output functions are permanently disabled due to a repetitive circuit overload fault. DTC B106F will be set with DTC B106E. When DTC B106F is present, the SJB must be replaced after the fault condition has been corrected. - DTC B1304 (Accessory Delay Relay Coil Circuit Short to Battery) - Accessory delay relay circuit short to battery voltage - DTC B2512 (Front Fog Lamp Relay Ckt Short to Battery) - Fog lamp relay circuit short to battery voltage - DTC B2973 (Daytime Running Lamp Output Shorted to Ground) - DRL output short to ground Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7186 This pinpoint test is intended to diagnose the following: - Output circuit short to ground or voltage - SJB PINPOINT TEST A: DTCs B106E/B106F NOTICE: If DTC B106F is present and the Smart Junction Box (SJB) is to be replaced, the fault condition must be corrected first. Failure to correct the fault condition first may cause damage to the new SJB, resulting in a repeat repair. ------------------------------------------------- A1 CHECK FOR DTC B106E - Review the DTCs from the SJB self-test. - Is DTC B106E present? Yes GO to A2. No GO to A3. ------------------------------------------------- A2 CHECK FOR OTHER DTCs - Review the DTCs from the SJB self-test. - Are any SJB DTCs present other than DTC B106E? Yes CORRECT any other DTCs. REFER to the Diagnostic Trouble Code (DTC) Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. REPEAT the self-test (on-demand DTCs). No CLEAR the DTCs. REPEAT the self-test. TEST the system for normal operation. ------------------------------------------------- A3 CHECK FOR DTC B106F - Review the DTCs from the SJB self-test. - Is DTC B106F present? Yes CORRECT any other DTCs. REFER to Diagnostic Trouble Code (DTC) Chart See: Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart. INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation. No The system is operating correctly at this time. The concern was caused by a fault in one of the output circuits. ------------------------------------------------- Pinpoint Test B: DTC B1317 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test B: DTC B1317 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7187 Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) monitors the voltage from the battery to determine if it goes above or below specific thresholds and sets DTC B1317 in continuous memory if the SJB detects high battery voltage above 15 volts on circuit SBB01 (RD). - DTC B1317 (Battery Voltage High) - a continuous memory DTC that sets when the SJB detects battery voltage above 15 volts on circuit SBB01 (RD). This pinpoint test is intended to diagnose the following: - Charging system concern - SJB PINPOINT TEST B: DTC B1317 NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump starting events. ------------------------------------------------- B1 CHECK FOR DTC B1317, B1676 OR P0563 SET IN OTHER MODULES - Ignition ON. - Enter the following diagnostic mode on the scan tool: (All Modules) Self-Test. - Retrieve the continuous memory DTCs from all modules. - Is DTC B1317, B1676 or P0563 (PCM) set in more than one module? Yes REFER to Charging System to diagnose an overcharging condition. No GO to B2. ------------------------------------------------- B2 CHECK THE BATTERY VOLTAGE - Turn off all interior/exterior lights and accessories. - Start and run the engine at approximately 2,000 rpm for 3 minutes while monitoring the battery voltage. - Does the battery voltage rise to 15 volts or higher? Yes REFER to Charging System to diagnose an overcharging condition. No GO to B3. ------------------------------------------------- B3 RECHECK FOR DTC B1317 - Turn the engine off. - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous memory DTCs. - Carry out the SJB self-test. - Is DTC B1317 present? Yes INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7188 No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump starting the vehicle. ------------------------------------------------Pinpoint Test C: DTC B1318 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test C: DTC B1318 Refer to Wiring Diagram Set 117, Remote Keyless Entry and Alarm for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The Smart Junction Box (SJB) monitors the voltage from the battery to determine if it goes above or below specific thresholds and sets DTC B1318 in continuous memory if the SJB detects low battery voltage below 10 volts on circuit SBB01 (RD). - DTC B1318 (Battery Voltage Low) - a continuous memory DTC that sets when the SJB detects battery voltage below 10 volts on circuit SBB01 (RD). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - High circuit resistance - SJB PINPOINT TEST C: DTC B1318 NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- C1 RECHECK THE SJB DTCs - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the DTCs. Repeat the SJB self-test. - Is DTC B1318 still present? Yes GO to C2. No The system is operating normally at this time. The DTC may have been set previously during battery charging or while jump starting the vehicle. ------------------------------------------------- C2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM - Enter the following diagnostic mode on the scan tool: PCM Self-Test. - Retrieve the continuous memory DTCs from the PCM. - Is DTC P0620, P0625, P0626 or P065B set in the PCM? Yes REFER to Charging System. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7189 No GO to C3. ------------------------------------------------- C3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE - Ignition OFF. - Check the battery condition and verify the battery is fully charged. Refer to Battery, Battery Condition Test. See: Starting and Charging/Battery/Testing and Inspection/Pinpoint Tests - Is the battery OK and fully charged? Yes GO to C4. No REFER to Charging System. ------------------------------------------------- C4 CHECK THE SJB VOLTAGE SUPPLY - Measure and record the voltage at the battery. - Disconnect: SJB C2280E. - Ignition ON. - Measure the voltage between the SJB C2280E-32, circuit SBB01 (RD), harness side and ground. - Is the voltage within 0.2 volt of the recorded battery voltage? Yes GO to C5. No REPAIR the circuit for high resistance. CLEAR the DTC. REPEAT the self-test. ------------------------------------------------- C5 CHECK THE SJB GROUND CIRCUIT - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the SJB C2280E-22, circuit GD108 (BK/VT), harness side and ground. - Is the resistance less than 5 ohms? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7190 CONNECT the negative battery cable. GO to C6. No REPAIR the circuit for high resistance. CONNECT the negative battery cable. TEST the system for normal operation. ------------------------------------------------- C6 CHECK FOR CORRECT SJB OPERATION - Disconnect the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test D: DTC U0155 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test D: DTC U0155 Normal Operation - DTC U0155 (Lost Communication With Instrument Panel Cluster (IC) Control Module) - set by the SJB whenever it receives invalid data from the Instrument Cluster (IC). This pinpoint test is intended to diagnose the following: - Module communication - SJB - IC PINPOINT TEST D: DTC U0155 ------------------------------------------------- D1 VERIFY CUSTOMER CONCERN - Ignition ON. - Verify that there is an observable symptom present. - Is an observable symptom present? Yes GO to D2. No The system is operating normally at this time. The DTC may have been set due to high network traffic or an intermittent fault condition. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7191 D2 CHECK THE COMMUNICATION NETWORK - Ignition ON. - Enter the following diagnostic mode on the scan tool: Network Test. - Carry out the network test. Does the IC pass the network test? Yes GO to D3. No REFER to Information Bus. ------------------------------------------------- D3 RETRIEVE THE RECORDED DTCs FROM THE SELF-TEST - Check for recorded SJB DTCs from the self-test. - Is DTC B1317 or B1318 recorded? Yes For DTC B1317, Go To Pinpoint Test b. See: Smart Junction Box (SJB)/Pinpoint Test B: DTC B1317 For DTC B1318, Go To Pinpoint Test c. See: Smart Junction Box (SJB)/Pinpoint Test C: DTC B1318 No GO to D4. ------------------------------------------------- D4 RECHECK THE SJB DTCs NOTE: If new modules were installed prior to the DTC being set, the module configuration may be incorrectly set during Programmable Module Installation (PMI) or the PMI may not have been carried out. - Clear the DTCs. Repeat the SJB self-test. - Is DTC U0155 still present? Yes GO to D5. No The system is operating correctly at this time. The DTC may have been set due to high network traffic or an intermittent fault condition. ------------------------------------------------- D5 CHECK FOR DTC U0155 SET IN OTHER MODULES - Clear all DTCs. - Ignition OFF. - Ignition ON. - Wait 10 seconds. - Enter the following diagnostic mode on the scan tool: Self-Test. - Retrieve the continuous memory DTCs from all modules. - Is DTC U0155 set in the ACM, DSM, audio DSP module or PAM? Yes INSTALL a new IC. No INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7192 ------------------------------------------------Pinpoint Test E: DTC U0164 Smart Junction Box (SJB) Pinpoint Tests Pinpoint Test E: DTC U0164 Normal Operation - DTC U0164 (Lost Communication With HVAC Control Module (EATC)) - set by the Smart Junction Box (SJB) if data messages received from the (module name) over the (network name) are missing for (insert specified time). This pinpoint test is intended to diagnose the following: - Module communication - SJB - HVAC module PINPOINT TEST E: DTC U0164 ------------------------------------------------- E1 VERIFY CUSTOMER CONCERN - Ignition ON. - Verify that there is an observable symptom present. - Is an observable symptom present? Yes GO to E2. No The system is operating normally at this time. The DTC may have been set due to high network traffic or intermittent fault condition. ------------------------------------------------- E2 CHECK THE COMMUNICATION NETWORK - Ignition ON. - Enter the following diagnostic mode on the scan tool: Network Test. - Carry out the network test. Does the (insert sending module name) pass the network test? Yes GO to E3. No REFER to Information Bus. ------------------------------------------------- E3 RETRIEVE THE RECORDED DTCs FROM THE SELF-TEST - Check for recorded SJB DTCs from the self-test. - Is DTC B1317 or B1318 recorded? Yes For DTC B1317, Go To Pinpoint Test b. See: Smart Junction Box (SJB)/Pinpoint Test B: DTC B1317 For DTC B1318, Go To Pinpoint Test c. See: Smart Junction Box (SJB)/Pinpoint Test C: DTC B1318 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Body Control Systems > System Information > System Diagnosis > Initial Inspection and Diagnostic Overview > Page 7193 No GO to E4. ------------------------------------------------- E4 RECHECK THE SJB DTCs NOTE: If new modules were installed prior to the DTC being set, the module configuration may be incorrectly set during Programmable Module Installation (PMI) or the PMI may not have been carried out. - Clear the DTCs. Repeat the SJB self-test. - Is DTC U0164 still present? Yes INSTALL a new HVAC module. TEST the system for normal operation. REPEAT the SJB self-test. If DTC U0164 is still present, INSTALL a new SJB. REFER to Smart Junction Box (SJB) See: Power and Ground Distribution/Power Distribution Module/Service and Repair. No The system is operating correctly at this time. The DTC may have been set due to high network traffic or intermittent fault condition. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7198 Auxiliary Step / Running Board Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7199 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7200 Auxiliary Step / Running Board Module: Service and Repair Power Running Board (PRB) Module Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the Power Running Board (PRB) module electrical connectors. 3. Remove the 3 screws and the PRB 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Locations > Running Board Motor, Left > Page 7205 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Running Board Motor, Left > Page 7208 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 7209 Auxiliary Step / Running Board Motor: Service and Repair Power Running Board (PRB) Motor NOTE: Mountaineer shown, Explorer similar. NOTE: RH shown, LH similar. Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: If the Power Running Board (PRB) cannot be extracted, extend the running board by hand. Extend the PRB. 3. Remove the straps and disconnect the PRB 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 PRB motor splash shield screws and remove the splash shield. 6. Remove the 3 bolts and PRB motor. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > Auxiliary Step / Running Board Motor > Component Information > Diagrams > Page 7210 7. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or patch materials are used, procedures may vary slightly. Remove the affected bumper. NOTE: Illustration is not vehicle specific. 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 cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch 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. Carry out 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 7217 Front Bumper Cover / Fascia: Removal and Replacement Bumper Cover - Front Removal and Installation Explorer/Explorer Sport Trac 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/Explorer Sport Trac 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. 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 (V6-4.0L (2009)) 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. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or patch materials are used, procedures may vary slightly. Remove the affected bumper. NOTE: Illustration is not vehicle specific. 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 cloth patch per manufacturer's instructions and apply to the affected area. - Immediately position the plastic repair material patch 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. Carry out 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Procedures > Page 7223 Rear Bumper Cover / Fascia: Removal and Replacement Bumper Cover - Rear, Sport Trac 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. 4. NOTICE: 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 (V6-4.0L (2009)) 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. NOTICE: 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 (V6-4.0L (2009)) 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 > Exterior Front Door Handle Front Door Exterior Handle: Service and Repair Exterior Front Door Handle 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 (V6-4.0L (2009)) 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 > Exterior Front Door Handle > Page 7236 Front Door Exterior Handle: Service and Repair Front Door Handles, Locks and Latches Exploded View Front Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Handles, Locks and Latches - Exploded View Front Door Interior Handle: Service and Repair Front Door Handles, Locks and Latches - Exploded View Front Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Handles, Locks and Latches - Exploded View > Page 7241 Front Door Interior Handle: Service and Repair Interior Door Handle - Front 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments Front Door Hinge: Adjustments Door Alignment Front and rear door 1. Depower the Supplemental Restraint System (SRS). For additional information, refer to Air Bag Systems. 2. Remove the door latch striker plate. Front door in and out, up and down adjustment 3. NOTE: The bolts securing the 2 hinge halves together are not to be removed or serviced. Remove the hinge-to-door or hinge-to-body bolts when removing or adjusting the front or rear doors. NOTE: Driver side shown, passenger side similar. Loosen, but do not remove, the front door hinge-to-front door fasteners enough to allow door adjustment. Front door fore, aft and tilt adjustment NOTE: Driver side shown, passenger side similar. 4. Loosen, but do not remove, the upper front door hinge-to-body fasteners enough to allow door adjustment. 5. If adjusting the driver side, remove the hood release lever. 1. Remove the screw. 2. Position the hood release lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7245 6. Remove the front door scuff plate. 7. Partially remove the front door weatherstrip. 8. Remove the lower cowl trim panel. 1. Remove the pin-type retainer. 2. Remove the lower cowl trim panel. 9. If adjusting the driver side, remove the hood release mechanism. 1. Remove the screw. 2. Position the hood release mechanism. 10. Disconnect the ground wires. 11. Position the weather shield and loosen, but do not remove, the front door lower hinge nut. 12. Loosen, but do not remove, the lower front door hinge-to-body fasteners enough to allow door adjustment. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7246 Rear door fore, aft and tilt adjustment 13. Remove the front door scuff plate. 14. Remove the rear door scuff plate. 15. Remove the lower B-pillar trim panel. 16. Remove the front safety belt retractor. - Remove the front safety belt retractor bolt. To install, tighten to 40 Nm (30 lb-ft). - Remove the safety belt retractor and position aside. 17. Loosen, but do not remove, the rear door hinge-to-body fasteners enough to allow door adjustment. Rear door in and out, up and down adjustment 18. Loosen, but do not remove, the rear door hinge-to-rear door fasteners enough to allow door adjustment. Front and rear door Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Adjustments > Page 7247 19. Adjust the door. 20. Tighten the door fasteners. - Tighten the front door hinge-to-front door fasteners to 30 Nm (22 lb-ft). - Tighten the front door hinge-to-body fasteners to 30 Nm (22 lb-ft). - Tighten the front door lower hinge nut to 30 Nm (22 lb-ft). - Tighten the rear door hinge-to-rear door fasteners to 30 Nm (22 lb-ft). - Tighten the rear door hinge-to-body fasteners to 30 Nm (22 lb-ft). 21. Reassemble the system. 22. Install and adjust the door striker as necessary. - Tighten the door latch striker plate screws to 25 Nm (18 lb-ft). 23. Repower the SRS. For additional information, refer to Air Bag Systems. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments Door Handle to Latch Rod Adjustment NOTE: An incorrectly adjusted exterior door handle can cause a loose handle, rattle noise, door hard to open from the outside door handle, or the outside door handle to not sit flush in the closed position. NOTE: Prior to carrying out the adjustment procedure, the door latch, exterior door handle, and linkages must be installed on the door. 1. Raise the door glass to the full-up position. 2. Remove the door trim panel. 3. Position the watershield aside. 4. Open the clip and disconnect the exterior door handle actuating rod. 5. Position the actuating rod and latch actuating lever in a neutral position. 6. NOTE: Do not push up or pull down on the actuating rod or latch actuating lever. Reinstall the exterior door handle actuating rod back into the clip. 7. Close the clip and test the system to make sure that the exterior door handle is operating correctly. 8. Reseal the watershield. 9. Install the door trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures Front Door Latch: Procedures Latch Lubrication 1. Open the door. 2. Using a screwdriver, fully close the latch (two clicks). 3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds. 4. Open the latch using either the interior or exterior door handle. 5. Open and close the door several times to circulate the lubricant inside the latch. 6. Wipe off any excess grease. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures > Page 7253 Front Door Latch: Removal and Replacement Front Door Handles, Locks and Latches - Exploded View Front Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Front Door Latch 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Procedures > Page 7254 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 (106 lb-in). 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 handle bezel cover. 2. Remove the front door trim panel handle bezel screws. 3. Remove the front door trim panel lower screws. NOTICE: To avoid damaging the front door trim panel, do not pull the bottom of the panel outward. 4. Remove the front door trim panel by lifting upward on the armrest to disengage the panel clips. 5. Disconnect the electrical connectors. 6. Disconnect the lock rod cable from the front door trim panel. 7. Disconnect the door handle conduit and cable from the front door trim panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Glass, Frames and Mechanisms Exploded View, Front Door Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Glass, Frames and Mechanisms Exploded View, Front Door > Page 7263 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation NOTE: For LH front only, the front window motor must be initialized whenever the front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run. 1. Remove the front door window glass. For additional information, refer to Window Glass - Front Door See: Service and Repair/Window Glass Front Door. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (106 lb-in). 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. - For LH front window only, initialize the LH front window motor. For additional information, refer to Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window Motor Initialization - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 7268 Front Door Window Motor: Service and Repair Window Regulator Motor - Front Door Window Regulator Motor - Front Door Removal and Installation NOTE: For LH front only, the front window motor must be initialized whenever the front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run. 1. Remove the front door window regulator. For additional information, refer to Window Regulator Front Door See: Front Door Window Regulator/Service and Repair/Window Regulator - Front Door. 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. - For LH front window only, initialize the LH front window motor. For additional information, refer to Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window Motor Initialization - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 7273 Front Door Window Regulator: Service and Repair Window Regulator - Front Door Window Regulator - Front Door Removal and Installation NOTE: For LH front only, the front window motor must be initialized whenever the front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run. 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. NOTICE: Make sure the holes in the glass bracket do not become enlarged during the rivet removal process. Damage to the window regulator will occur 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. 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. - For LH front window only, initialize the LH front window motor. For additional information, refer to Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window Motor Initialization - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 > Exterior Rear Door Handle Rear Door Exterior Handle: Service and Repair Exterior Rear Door Handle 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 (V6-4.0L (2009)) 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 > Exterior Rear Door Handle > Page 7280 Rear Door Exterior Handle: Service and Repair Rear Door Handles, Locks and Latches - Exploded View Rear Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Adjustments Rear Door Latch: Adjustments Door Handle to Latch Rod Adjustment NOTE: An incorrectly adjusted exterior door handle can cause a loose handle, rattle noise, door hard to open from the outside door handle, or the outside door handle to not sit flush in the closed position. NOTE: Prior to carrying out the adjustment procedure, the door latch, exterior door handle, and linkages must be installed on the door. 1. Raise the door glass to the full-up position. 2. Remove the door trim panel. 3. Position the watershield aside. 4. Open the clip and disconnect the exterior door handle actuating rod. 5. Position the actuating rod and latch actuating lever in a neutral position. 6. NOTE: Do not push up or pull down on the actuating rod or latch actuating lever. Reinstall the exterior door handle actuating rod back into the clip. 7. Close the clip and test the system to make sure that the exterior door handle is operating correctly. 8. Reseal the watershield. 9. Install the door trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures Rear Door Latch: Procedures Latch Lubrication 1. Open the door. 2. Using a screwdriver, fully close the latch (two clicks). 3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds. 4. Open the latch using either the interior or exterior door handle. 5. Open and close the door several times to circulate the lubricant inside the latch. 6. Wipe off any excess grease. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures > Page 7289 Rear Door Latch: Removal and Replacement Rear Door Handles, Locks and Latches - Exploded View Rear Door Handles, Locks and Latches - Exploded View 1. For additional information, refer to the procedures. Rear Door Latch 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 (106 lb-in). 7. Release the rear door push button rod from the door frame retainer. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Procedures > Page 7290 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Page 7294 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. NOTICE: 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 (V6-4.0L (2009)) 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 > Door Glass Top Run - Rear Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear Door Glass Top Run - Rear Removal and Installation 1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear Door See: Service and Repair/Window Glass Rear Door. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (106 lb-in). 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 (V6-4.0L (2009)) 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 > Door Glass Top Run - Rear > Page 7300 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door NOTE: Explorer shown, Explorer Sport Trac similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door Rear Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door NOTE: Explorer shown, Explorer Sport Trac similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 7305 Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear Door Window Regulator Motor - Rear Door 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door Rear Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door NOTE: Explorer shown, Explorer Sport Trac similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 7310 Rear Door Window Regulator: Service and Repair Window Regulator - Rear Door Window Regulator - Rear Door 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. NOTICE: Make sure the hole in the glass bracket does not become enlarged during the rivet removal process. Damage to the window regulator will occur 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 rear window regulator mounting 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations Power Sliding Door Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations > Page 7315 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations > Page 7316 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations > Page 7317 Power Sliding Door Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations > Page 7318 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair Fuel Filler Door Cup Bezel Removal 1. NOTICE: Apply tape around the circumference of the fuel filler door. Failure to follow this direction may result in damage to the vehicle. Remove the fuel filler door screws and reposition the fuel filler door. 2. Using a 90 degree pick tool, release the upper RH fuel filler door cup bezel clip from the body. 3. Using a non-marring body tool, prevent the fuel filler door cup bezel from re-attaching to the body. 4. Using a 90 degree pick tool, release the bottom RH fuel filler door cup bezel clip from the body. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Page 7322 5. Pull outward and upward to remove the fuel filler door cup bezel from the body. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Hood Latch: Service and Repair Hood Latch 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 (106 lb-in). 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch > Page 7328 Hood Latch: Service and Repair Hood Latch and Components - Exploded View Hood Latch and Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch and Components - Exploded View Hood Latch Release: Service and Repair Hood Latch and Components - Exploded View Hood Latch and Components - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Hood Latch and Components - Exploded View > Page 7333 Hood Latch Release: Service and Repair Hood Latch Release Handle Hood Latch Release Handle Removal and Installation 1. Remove the hood latch. For additional information, refer to Hood Latch See: Hood Latch/Service and Repair/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 (V6-4.0L (2009)) 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 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. NOTE: Open and support the liftgate window glass before removing the liftgate window glass struts. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Liftgate Glass Actuator > Page 7342 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Liftgate Glass Actuator > Page 7345 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Page 7346 Power Trunk / Liftgate Lock Actuator: Service and Repair Liftgate Latch Actuator Removal and Installation 1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 7350 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 7351 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Window Latch Actuator Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 7355 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View Trunk / Liftgate Handle: Service and Repair Liftgate Handle, Lock and Latch - Exploded View Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 7360 Trunk / Liftgate Handle: Service and Repair Liftgate Release Handle 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 (V6-4.0L (2009)) 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. NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View Trunk / Liftgate Latch: Service and Repair Liftgate Handle, Lock and Latch - Exploded View Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 7368 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 (106 lb-in). 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Liftgate Handle, Lock and Latch - Exploded View > Page 7369 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 (106 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System Information > Service and Repair Trunk / Liftgate Lock: Service and Repair Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Fender Splash Shield Front Fender Liner: Service and Repair Fender Splash Shield Fender Splash Shield 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Fender Splash Shield > Page 7383 Front Fender Liner: Service and Repair Front End Body Panels - Exploded View Front End Body Panels - Exploded View Explorer/Explorer Sport Trac Mountaineer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Fender Splash Shield > Page 7384 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation Frame and Body Mounting The frame consists of 2 steel-channel rails, 10 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7389 Structural Enhancement - Explorer Sport Trac The purpose of these inserts is to enhance the structural rigidity of the frame in this area. Inserts cannot be repaired or installed new. NOTICE: When removing upper body mounts, enough adjacent body mount support bolts and 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7390 Body Support - Front End Sheet Metal (FESM) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7391 Body Support - No. 1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7392 Body Support - No. 2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7393 Body Support - No. 3 (Explorer/Mountaineer ONLY) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7394 Body Support - No. 3 (Explorer Sport Trac ONLY) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation > Page 7395 Body Support - No. 4 (Explorer/Mountaineer ONLY) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications Cross-Member: Specifications Torque Specifications Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Cross-Member: Service and Repair Transmission Support Crossmember 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 (133 lb-in). 3. NOTE: Explorer/Mountaineer shown, Explorer Sport Trac similar. Remove the heat shield bolt from the RH heat shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 7401 - To install, tighten to 18 Nm (159 lb-in). 4. Remove the heat shield bolt from the LH heat shield. - To install, tighten to 18 Nm (159 lb-in). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember > Page 7402 Cross-Member: Service and Repair Crossmember - 1B Crossmember - 1B Crossmember 1B Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Vehicle Jacking and Lifting. 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 (V6-4.0L (2009)) 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 rear 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7406 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7407 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7408 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7409 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7410 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7411 SPORT TRAC TEMPLATE # 3, LEFT HAND OUTER SIDE VIEW, RIGHT HAND INNER SYMMETRICALLY OPPOSITE TO LEFT HAND INNER All vehicles 8. Deburr 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 or pull together the frame rails slightly to get the brackets to fit. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7412 Insert the new trailer hitch crossmember 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 7416 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations > Page 7417 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Opening Panel Grille: Service and Repair Radiator Grille Opening Panel Radiator Grille Opening Panel Removal and Installation 1. Remove the headlamp assemblies. 2. Remove the front bumper cover. 3. Remove the 5 grille panel deflector pin-type retainers. 4. Remove the grille panel deflector. 5. Remove the 8 grille opening panel bolts. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the grille opening panel center bolt. - To install, tighten to 9 Nm (80 lb-in). 7. Remove the grille opening panel. 8. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Opening Panel > Page 7422 Grille: Service and Repair Radiator Grille Radiator Grille - Explorer, Explorer Sport Trac NOTE: For Mountaineer, refer to Radiator Grille - Mountaineer See: . Removal and Installation 1. Remove the front bumper cover. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Opening Panel > Page 7423 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead Console: Service and Repair Console - Overhead Console - Overhead Overhead Console With Roof Opening Panel Overhead Console Without Roof Opening Panel Removal and Installation Vehicles with roof opening panel 1. Pull the overhead console downward to release the retaining clips. Vehicles without roof opening panel 2. Open the overhead console garage door opener storage compartment. 3. Remove the overhead console screw. All vehicles 4. Remove the overhead console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7429 5. Disconnect the electrical connectors. 6. To install, reverse the removal procedure. - On vehicles with a roof opening panel, make sure to align the overhead console retaining clips to the adjacent retaining clip holes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7430 Console: Service and Repair Console - Front, Floor Console - Front, Floor Removal and Installation 1. Move the front seats to the full rearward position. 2. Remove the LH and RH front floor console rear bolts. 3. Position the front seats to the full rearward position. 4. Remove the selector lever bezel. 5. Open and lift the front floor console stowage door upward. 6. Remove the 2 front floor console finish panel screws. 7. Remove the front floor console finish panel. - Disconnect the electrical connector. 8. Disconnect the front floor console electrical connectors. 9. Remove the 2 front floor console-to-instrument panel screws. 10. Remove the LH and RH front floor console pushpin retainers. 11. Remove the LH and RH front floor console extension trim panels. 12. Remove the LH and RH front floor console middle bolts. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7431 13. Remove the front floor console. - Pull the front floor console toward the rear of the vehicle. 14. To install, reverse the removal procedures. - Make sure to align the trim panel retaining clips to the adjacent retaining clip holes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console - Overhead > Page 7432 Console: Service and Repair Console - Rear, Floor Console - Rear, Floor Removal and Installation NOTE: The rear floor console bracket does not need to be removed to remove the console. 1. Open the armrest and remove the storage compartment insert. 2. Remove the 4 rear floor console bolts. - To install, tighten to 9 Nm (80 lb-in). 3. NOTICE: To prevent damage to the 2 plastic guide pegs located on the bottom of the console, pull the console straight up when removing. Disconnect the electrical connector and remove the rear floor console. 4. NOTICE: To prevent damage to the 2 plastic guide pegs located on the bottom of the console, install the console straight down until the pegs are correctly seated in the holes. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. 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 this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagram. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition to OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7438 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7439 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the cover and RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7440 7. Remove the 2 driver air bag module bolts (1 shown). 8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Open and lower the glove compartment door. 10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield. 11. NOTE: The canister vent and adaptive tether do not require deactivation. Disconnect the LH side passenger air bag module electrical connector. 12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Disengage the passenger seat side air bag module electrical connector locking clip, release the tab and disconnect the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 13. Release and position aside the passenger side C-pillar trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7441 14. Disconnect the passenger side safety canopy module electrical connector. 15. Release and position aside the driver side C-pillar trim panel. 16. Disconnect the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 17. Remove the driver and passenger side upper C-pillar trim panels. 18. Disconnect the passenger side safety canopy module electrical connector. 19. Disconnect the driver side safety canopy module electrical connector. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7442 20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module electrical connector locking clip, release the tab and disconnect the driver seat side air bag module electrical connector. 21. Install the RCM fuse 17 (10A) to the SJB. 22. 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. 3. Connect the driver seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles 4. Connect the driver side safety canopy module electrical connector. 5. Connect the passenger side safety canopy module electrical connector. 6. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 7. Connect the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7443 8. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 11. Connect the passenger seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Attach the passenger seat side air bag module electrical connector to the seat track bracket. 12. Connect the LH side passenger air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7444 13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer. 14. NOTICE: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. 15. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 16. Turn the ignition switch from OFF to ON. 17. Install RCM fuse 17 (10A) to the SJB and install the cover. 18. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 19. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner Explorer/Mountaineer NOTE: Headliner with roof opening panel shown, headliner without opening panel similar. Explorer Sport Trac NOTE: Headliner without roof opening panel shown, headliner with opening panel similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7448 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. For additional information, refer to A-Pillar Trim Panel See: Trim Panel/Service and Repair/A-Pillar Trim Panel. 5. Position the B-pillar upper trim panel aside. For additional information, refer to B-Pillar Upper Trim Panel See: Trim Panel/Service and Repair/B-Pillar Upper Trim Panel. Explorer and Mountaineer only 6. Remove the C-pillar trim panel. For additional information, refer to C-Pillar Trim Panel - Explorer, Mountaineer . 7. Remove the D-pillar trim panel. For additional information, refer to D-Pillar Trim Panel See: Trim Panel/Service and Repair/D-Pillar Trim Panel. Explorer Sport Trac 8. Position the C-pillar upper trim panel aside. For additional information, refer to C-Pillar Upper Trim Panel - Explorer Sport Trac See: Trim Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7449 Panel/Service and Repair/C-Pillar Upper Trim Panel. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7450 All vehicles 21. Disconnect the electrical connector and the wiring pin-type retainers on the A-pillar. 22. NOTICE: To prevent bending or damaging the headliner, an assistant is required to support the headliner while carrying out the remaining steps. 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. NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest: > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 7459 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-2-9 > Feb > 09 > Interior - Sun Visor Mirror Cover Cracked > Page 7465 CONDITION BASIC PART NO. CODE 7804104 D4 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Visor: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling Wheel Cover: All Technical Service Bulletins Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling TSB 10-11-2 06/21/10 20 INCH POLISHED ALUMINUM WHEEL - CORROSION AND ETCHING FORD: 2008-2010 Explorer Sport Trac, Explorer MERCURY: 2008-2010 Mountaineer ISSUE Some 2008-2010 Explorer, Mountaineer and Explorer Sport Trac vehicles equipped with 20-inch aluminum wheels may exhibit the clear coat peeling off the wheel and/or cracks in the clear coat that look like spider webs. This may be due to a galvanic corrosion reaction between the aluminum wheel and the chrome center wheel cap. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Replace the affected wheel or wheels and install new center wheel caps that prevent the corrosion. 1. Inspect wheel(s) for cracked or peeling clear coat. (Figure 1) NOTE CONDITIONS ATTRIBUTABLE TO DAMAGE ARE NOT ELIGIBLE FOR COVERAGE UNDER WARRANTY. REFER TO WARRANTY AND POLICY MANUAL FOR ADDITIONAL INFORMATION. 2. To service, replace only affected wheel or wheels and install new center wheel caps. Refer to Workshop Manual, Section 204-04, for wheel removal and installation procedures including tire/wheel disassembly/assembly to prevent damage to the tire pressure monitoring system (TPMS) sensor. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Visor: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 7471 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Visor: > 10-11-2 > Jun > 10 > Wheels - 20 Inch Wheels Clear Coat Cracking/Peeling > Page 7477 101102A 2008-2010 0.6 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace One Wheel And Center Wheel Cap (Do Not Use With Any Other Labor Operations) 101102B 2008-2010 0.9 Hr. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Two Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) 101102C 2008-2010 1.2 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Three Wheels And Center Wheels Caps (Do Not Use With Any Other Labor Operations) 101102D 2008-2010 1.5 Hrs. Explorer/Mountaineer/Explorer Sport Trac: Inspect All Wheels. Replace Four Wheels And Center Wheel Caps (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 1007 14 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View Trim Panel: Service and Repair Interior Trim - Exploded View Interior Trim - Exploded View Explorer and Mountaineer Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7482 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7483 Trim Panel: Service and Repair A-Pillar Trim Panel A-Pillar Trim Panel 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7484 Trim Panel: Service and Repair B-Pillar Lower Trim Panel B-Pillar Lower Trim Panel 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7485 Trim Panel: Service and Repair B-Pillar Upper Trim Panel B-Pillar Upper Trim Panel Removal and Installation 1. Remove the B-pillar lower trim panel. For additional information, refer to B-Pillar Lower Trim Panel See: 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7486 Trim Panel: Service and Repair Interior Trim - Exploded View Interior Trim - Exploded View Explorer and Mountaineer Explorer Sport Trac Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7487 1. For additional information, refer to the procedures. A-Pillar Trim Panel A-Pillar Trim Panel 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7488 6. To install, reverse the removal procedure. B-Pillar Lower Trim Panel B-Pillar Lower Trim Panel 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 Removal and Installation 1. Remove the B-pillar lower trim panel. For additional information, refer to B-Pillar Lower Trim Panel See: 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. 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 Upper Trim Panel C-Pillar Upper Trim Panel - Explorer Sport Trac 1. Remove the C-pillar lower trim panel. For additional information, refer to C-Pillar Lower Trim Panel - Explorer Sport Trac See: C-Pillar Lower Trim Panel. 2. Remove the roof trim panel. 3. Remove the C-pillar upper trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7489 - Route the safety belt through the upper trim panel. 4. To install, reverse the removal procedures. C-Pillar Lower Trim Panel C-Pillar Lower Trim Panel - Explorer Sport Trac 1. Remove the rear seat. 2. Remove the rear cab trim panel. For additional information, refer to Cab Rear Trim Panel See: Cab Rear 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. Cab Rear Trim Panel Cab Rear Trim Panel 1. Position the second row seat back forward. 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 Removal and Installation All vehicles 1. Remove the front door scuff plate. Passenger side 2. Remove the cowl trim panel. Driver side 3. Remove the hood release lever. 1. Remove the screw. 2. Remove the hood release lever. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7490 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 Removal and Installation Vehicles with third row seating 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Interior Trim - Exploded View > Page 7491 5. Remove the D-pillar trim panel. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component Information > Service and Repair Utility Storage Compartment: Service and Repair Instrument Panel - Exploded View NOTE: Explorer/Explorer Sport Trac shown, Mountaineer similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control Key: Testing and Inspection Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure will not function. This switch is set to ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures. 1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is ENABLED, when viewing the IC PID SPAREKEY. From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - the spare key programming procedure is not accessible. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7504 Key: Testing and Inspection Key Programming Using Diagnostic Equipment Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle will not start until a minimum of 2 keys are programmed into the Instrument Cluster (IC). NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be available to carry out this procedure. One or both of them may be the customer's original keys. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Turn the key to the OFF position and disconnect the scan tool. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. The vehicle should now start with both PATS ignition keys. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7505 Key: Testing and Inspection Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch; ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC during this programming procedure, but only if the IC PID SPAREKEY is ENABLED. NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure will end. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2 keys have been programmed), no matter how many keys are programmed to the vehicle. 1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder. 3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 4. Turn the key to the OFF position and remove the key from the ignition lock cylinder. 5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new key) into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), repeat Steps 1-5 for each additional key that needs to be programmed. 7. Start the vehicle with the new key(s). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7506 Key: Testing and Inspection Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder(s). NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed into all of their vehicles keys (or, to all of the keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle) need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is turned on, and must be turned off before viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It should not be the same key code. 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the on-screen instructions. 5. Select: "unlimited key mode ON" and follow the on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to be removed at this time). 8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON position for 3 seconds. 9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 11. The vehicle should now start with both PATS keys. 12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7507 NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need to be removed at this time). 5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the Instrument Cluster (IC) using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be enabled. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7508 Key: Testing and Inspection Key Programming Switch State Control Key Programming Switch State Control NOTE: The spare key programming switch is a programmable switch which provides the capability to enable/disable the normal customer spare key programming procedure detailed in the Owner's Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This programmable switch is provided as a convenience for rental company fleets or other fleet purchasers who may not want the spare key programming procedure available to the vehicle driver. NOTE: The spare key programming switch state can be viewed with the IC PID SPAREKEY. NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC using Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED, the Key Programming Using Two Programmed Keys procedure will not function. This switch is set to ENABLE when the vehicle is built. This PID does not affect the Key Programming Using Diagnostic Equipment, the Spare Key Programming - Unlimited Key Mode or the Spare Key Programming Using Diagnostic Equipment procedures. 1. Insert a programmed Passive Anti-Theft System (PATS) key into the ignition lock cylinder and turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: The default setting of the key programming switch on delivery of all new vehicles is ENABLED, when viewing the IC PID SPAREKEY. From the scan tool menu select: "Customer Spare Key Programming Enable" (or "Customer Spare Key Programming Disable"), and follow the on-screen instructions. "Customer Spare Key Programming Enable" - the spare key programming procedure is accessible. - "Customer Spare Key Programming Disable" - the spare key programming procedure is not accessible. Key Programming Using Diagnostic Equipment Key Programming Using Diagnostic Equipment NOTE: This procedure is used when a customer needs keys programmed into the system and does not have 2 programmed ignition keys available. This procedure is also useful when a programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase key code(s) from the Passive Anti-Theft System (PATS) memory. NOTE: This procedure erases all programmed ignition keys from the vehicle memory. The vehicle will not start until a minimum of 2 keys are Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7509 programmed into the Instrument Cluster (IC). NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: Two PATS encoded (contains a transponder) keys with the correct mechanical cut must be available to carry out this procedure. One or both of them may be the customer's original keys. NOTE: If additional keys are to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If the remaining keys are with the customer and are not available with the vehicle, instruct the customer to refer to the Owner's Literature for instructions on programming the remaining keys. In this case, the PID SPAREKEY must be enabled. NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. From the scan tool menu select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Turn the key to the OFF position and disconnect the scan tool. 5. Insert the first PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the next PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. The vehicle should now start with both PATS ignition keys. 9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Key Programming Using Two Programmed Keys Key Programming Using Two Programmed Keys NOTE: This procedure only works if 2 or more programmed ignition keys are available. If 2 programmed keys are not available, refer to Key Programming Using Diagnostic Equipment See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment. NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate. If this IC PID is not enabled, refer to Key Programming Switch State Control See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Switch State Control, then select SPAREKEY programming switch; ENABLED. The IC PID SPAREKEY is set to ENABLE when the vehicle is built. NOTE: If the programming procedure is successful, the new key(s) will start the vehicle and the anti-theft indicator will prove-out for approximately 3 seconds. If the programming procedure is not successful and the new key(s) does not start the engine, leave the key in the ON position for at least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the failure repeats, refer to Anti-Theft See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection in the Diagnosis and Testing to review the DTCs and carry out the appropriate pinpoint tests. NOTE: A maximum of 8 Passive Anti-Theft System (PATS) keys can be programmed into the IC during this programming procedure, but only if the IC PID SPAREKEY is ENABLED. NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle will start. NOTE: If the vehicle is in unlimited key mode, this spare key programming procedure still functions. Any 2 keys that can start the vehicle can be used to program an additional unlimited key. NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or are not available, instruct the customer to refer to the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7510 Owner's Literature for instructions on programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled. NOTE: If the steps are not carried out as outlined, the programming procedure will end. NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be PATS encoded keys (contain a transponder). NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of the transceiver does not erase the PATS key codes in the IC. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2 keys have been programmed), no matter how many keys are programmed to the vehicle. 1. Insert the first programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 2. Turn the key to the OFF position and remove the first key from the ignition lock cylinder. 3. Within 5 seconds of turning the key to the OFF position, insert the second programmed key into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 4. Turn the key to the OFF position and remove the key from the ignition lock cylinder. 5. Within 10 seconds of turning the key to the OFF position, insert the unprogrammed key (the new key) into the ignition lock cylinder and turn the key from the OFF position to the ON position (maintain the key in the ON position for a minimum of 3 seconds and less than 10 seconds). 6. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the IC), repeat Steps 1-5 for each additional key that needs to be programmed. 7. Start the vehicle with the new key(s). Spare Key Programming - Unlimited Key Mode Spare Key Programming - Unlimited Key Mode Enabling Unlimited Key Mode NOTE: Unlimited key mode is intended for use by those customers who need more than 8 keys for their vehicle. NOTE: Before programming, the new key(s) must have the correct mechanical cut for the ignition lock cylinder(s). NOTE: The unlimited key mode is set up by creating a special, unique unlimited transponder security key code and programming this key code into all of the vehicle keys so they contain the same key code. NOTE: When in the unlimited key mode, the N_KEYCODE PID always reads 2, no matter how many keys are programmed to the vehicle (after the first 2 keys have been programmed). 1. The customer must choose an 8-digit number (except for 00000000 or 00000001) to be programmed into all of their vehicles keys (or, to all of the keys they want programmed to one vehicle). All customer vehicles keys (or all keys for one vehicle) need to use the same number. Valid digits are 0-9 and the letters A-F. 2. NOTE: If the Instrument Cluster (IC) UNL_KEY_ID PID is not available, unlimited key mode is turned on, and must be turned off before viewing the stored code. At this time, unlimited keys may be programmed to the vehicle(s). To view/change the stored code, follow the procedure for disabling the unlimited key mode below. Monitor the IC UNL_KEY_ID PID and compare its value against the code chosen in Step 1. It should not be the same key code. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7511 3. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 4. Once in security access, select: "program unlimited key code" and follow the on-screen instructions. Enter the 8-digit code chosen by the customer in Step 1 of this procedure and follow the on-screen instructions. 5. Select: "unlimited key mode ON" and follow the on-screen instructions. 6. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 7. Disconnect the scan tool and turn the ignition key to the OFF position (the key does not need to be removed at this time). 8. Turn the first Passive Anti-Theft System (PATS) key in the ignition lock cylinder to the ON position for 3 seconds. 9. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 10. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 11. The vehicle should now start with both PATS keys. 12. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key that needs to be programmed. Disabling Unlimited Key Mode NOTE: By disabling the unlimited key mode, the previous access code no longer operates the vehicle. 1. From the scan tool, enter TOOLBOX. Select BODY-SECURITY-PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. This procedure takes approximately 10 minutes to carry out, during which time the ignition key must be in the ON position and the scan tool must be connected to the vehicle. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 2. Select: "unlimited key mode OFF" and follow the on-screen instructions. 3. Select: "Ignition Key Code Erase" and follow the on-screen instructions. 4. Disconnect the scan tool and turn the ignition switch to the OFF position (the key does not need to be removed at this time). 5. Turn the first PATS key in the ignition lock cylinder to the ON position for 3 seconds. 6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder. 7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for 3 seconds. 8. NOTE: With the unlimited key mode turned off, a maximum of 8 keys can be programmed into the Instrument Cluster (IC) using the Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys procedure. The IC SPAREKEY PID must be enabled. If it is desired to program additional key(s), refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for each additional key (up to 8 keys, total) that needs to be programmed. The IC SPAREKEY PID must be enabled. Spare Key Programming - Using Diagnostic Equipment Spare Key Programming - Using Diagnostic Equipment Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7512 NOTE: This procedure is used when a customer needs to have an additional key programmed into the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This procedure is also useful when attempting to determine if an ignition key is damaged, as a new key can be installed without erasing keys or without having 2 programmed keys available. NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock cylinder. NOTE: If 8 keys are already programmed, this procedure does not allow any more ignition keys to be programmed. The number of keys that are programmed into the Passive Anti-Theft System (PATS) can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE. NOTE: When in the unlimited key mode, the N_KEYCODE PID will always read 2 (after the first 2 keys have been programmed), no matter how many keys are programmed to the vehicle. 1. Turn the unprogrammed PATS key from the OFF position to the ON position. 2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics. 3. NOTE: Make sure the selection made is "PROGRAM" (Program additional ignition key). If the "ERASE" (Ignition Key Code Erase) selection is made, all of the keys will be erased from the system. From the scan tool menu select: "Program additional ignition key" and follow the on-screen instructions. 4. Turn the key to the OFF position and disconnect the scan tool. 5. Start the vehicle with the new PATS key. The vehicle will now start with the new PATS key and also with the original PATS keys. Passive Anti-Theft System (PATS) Parameter Reset Passive Anti-Theft System (PATS) Parameter Reset NOTE: When using the Integrated Diagnostic System (IDS), the Instrument Cluster (IC) and the PCM parameters are reset at the same time. 1. Turn the key from the OFF position to the ON position. 2. From the scan tool, follow the on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Component Tests and General Diagnostics . 3. From the scan tool, select: Parameter Reset and follow the on-screen instructions. 4. NOTE: If the IC was replaced, follow Steps 4-9. If the IC and the PCM were replaced, follow Steps 4-9. If only the PCM was replaced, go to Step 9. From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key Programming Switch State Control > Page 7513 5. Turn the key to the OFF position and disconnect the scan tool. 6. Turn the key to the ON position for a minimum of 3 seconds. 7. Turn the key to the OFF position and remove the key. 8. Insert the second key into the ignition lock cylinder and turn the key to the ON position for a minimum of 3 seconds. 9. Both keys will now start the vehicle. 10. If more keys are required to be programmed, refer to Key Programming Using Two Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 7518 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 7519 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 3 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Locations > Page 7520 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter Programming Remote Keyless Entry (RKE) Transmitter Programming NOTE: All Remote Keyless Entry (RKE) transmitters must be programmed at the same time. NOTE: 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 the 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 Locks, Latches and Entry Systems See: Power Locks/Testing and Inspection. Make sure that no more than the maximum number of 6 RKE transmitters are attempted to be programmed. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7525 Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming Autolock and Auto-Unlock 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7526 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7527 Keyless Entry Transmitter: Testing and Inspection 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7528 Keyless Entry Transmitter: Testing and Inspection 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 7529 Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming Stepped Unlock Programming 1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the Remote Keyless Entry (RKE) transmitter simultaneously for 4 seconds. The parking lamps will flash twice to indicate the mode change. 2. Repeat Step 1 to enable/disable the stepped unlocking feature. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7535 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7536 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Door Lock Actuator, Right Front > Page 7537 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7540 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7541 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Door Lock Actuator, Left Front > Page 7542 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. For additional information, refer to Front Door Latch See: Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Front Door Lock Actuator > Page 7545 Power Door Lock Actuator: Service and Repair Rear Door Lock Actuator Rear Door Lock Actuator Removal and Installation 1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side > Page 7550 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side > Page 7553 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7554 Power Door Lock Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7555 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7556 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. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Service and Repair Trunk / Liftgate Lock: Service and Repair Liftgate Handle, Lock and Latch - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7565 Memory Positioning Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7566 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7567 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7568 Memory Positioning Module: Service and Repair Driver Seat Module (DSM) Removal and Installation NOTICE: 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 Driver Seat Module (DSM) after installation. 1. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: When a new DSM is installed, it is necessary to download the module configuration information from the scan tool into the new DSM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7569 To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 7573 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair Exterior Mirror Motor Removal and Installation NOTE: RH shown, LH similar. 1. Remove the exterior mirror glass. For additional information, refer to Exterior Mirror Glass See: Service and Repair/Exterior Mirror Glass. 2. Remove the exterior mirror motor screws. 3. Disconnect the exterior mirror motor electrical connectors. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7580 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7581 Power Mirror Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7582 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7583 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7584 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch Removal and Installation 1. Remove the front door trim panel. 2. Depress the 2 retaining tabs and 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7589 Memory Positioning Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7590 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7591 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7592 Memory Positioning Module: Service and Repair Driver Seat Module (DSM) Removal and Installation NOTICE: 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 Driver Seat Module (DSM) after installation. 1. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: When a new DSM is installed, it is necessary to download the module configuration information from the scan tool into the new DSM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 7593 To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Power Seat Relay: Locations Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 7598 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 7599 Power Seat Relay: Locations Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 7600 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 7603 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 7606 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 7607 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 7608 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7612 Auxiliary Step / Running Board Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7613 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Auxiliary Step / Running Board Module > Component Information > Locations > Page 7614 Auxiliary Step / Running Board Module: Service and Repair Power Running Board (PRB) Module Removal and Installation 1. Remove the RH C-pillar trim panel. 2. Disconnect the Power Running Board (PRB) module electrical connectors. 3. Remove the 3 screws and the PRB 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion NOTE: Power seat track shown, manual seat track similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 7618 NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 7619 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 7620 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Page 7621 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7625 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7626 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 7630 Trailer Towing Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations > Page 7631 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7638 Sunroof / Moonroof Motor: Service and Repair Roof Opening Panel Motor Roof Opening Panel Motor Removal and Installation NOTICE: 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. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. 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. NOTE: 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. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Track: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7646 Sunroof / Moonroof Track: Service and Repair Trough Assembly Trough Assembly Removal and Installation 1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel Glass See: Sunroof / Moonroof Panel/Service and Repair/Roof Opening Panel Glass. 2. Remove the trough assembly. - Pull the trough assembly arms outward to release the trough assembly guide arm pins from the roof opening panel frame to remove. 3. To install, reverse the removal procedure. - Align the roof opening panel. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Windguard: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7651 Sunroof / Moonroof Windguard: Service and Repair Air Deflector Air Deflector Removal and Installation 1. Move the 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. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7656 Sunroof / Moonroof Frame: Service and Repair Roof Opening Panel Frame Roof Opening Panel Frame 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. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 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. 5. Remove the entertainment center support bracket (if equipped). - Remove the 7 bolts. - Remove the support bracket. NOTICE: 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. - Align the roof opening panel. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Sunroof / Moonroof Module: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7660 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7661 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel - Exploded View Roof Opening Panel - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7666 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Glass Roof Opening Panel Glass 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. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. 1. Position 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. - Align the roof opening panel. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7667 Sunroof / Moonroof Panel: Service and Repair Roof Opening Panel Shield Roof Opening Panel Shield Removal and Installation 1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel Glass See: 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Roof Opening Panel - Exploded View > Page 7668 8. To install, reverse the removal procedure. - Align the roof opening panel. For additional information, refer to Roof Opening Panel Alignment See: Adjustments. - Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel Motor Initialization See: Testing and Inspection/Programming and Relearning. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair Head Rest: Service and Repair Head Restraint Guide Sleeve Removal NOTE: Typical head restraint guide sleeve shown, others similar. 1. Push in on the 2 head restraint guide sleeve release buttons and remove the head restraint. 2. Obtain a flat-head screwdriver with a width of 4 mm (0.157 in) to 7 mm (0.275 in) and a thickness of approximately 1 mm (0.039 in). 3. Align the screwdriver to the middle of the head restraint guide sleeve release button. 4. Position the screwdriver between the head restraint guide sleeve neck and backrest trim cover and foam pad. 5. Position the screwdriver at a 45-degree angle. 6. NOTE: For retainer clarity, backrest trim cover and foam pad are removed. Push the screwdriver in, bending the lock feature on the head restraint guide sleeve in. 7. While bending the lock feature in, push down on the screwdriver handle, prying the head restraint guide sleeve up and disengaging it from the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Page 7673 backrest frame crossmember. 8. Remove the head restraint guide sleeve. - Discard the head restraint guide sleeve. 9. Repeat these steps for the head restraint guide sleeve on the opposite side. Installation NOTICE: Always install new head restraint guide sleeves. Difficult adjustment of the head restraint may occur. Failure to follow these instructions may result in component failure. NOTICE: The head restraint guide sleeves are not interchangeable. Failure to install the correct head restraint guide sleeve at the correct position may result in component failure. 1. Make sure the holes in the backrest foam pad and backrest trim cover are aligned to the holes in the backrest frame. 2. Install the head restraint guide sleeve with the large button and wide key on the LH side of the seat. 3. Install the head restraint guide sleeve with the small button and thin key on the RH side of the seat. 4. NOTICE: Do not attempt to seat the head restraint guide sleeve by hand. This may result in excessive head restraint adjustment efforts and permanent damage to the head restraint guide sleeve. To allow the head restraint guide sleeve to slide freely through the backrest foam pad and backrest trim cover, twist the head restraint guide sleeve while pushing it into the backrest frame hole as far as it will go with hand pressure. 5. NOTICE: Striking effort should not result in any type of damage or distortion to the head restraint guide sleeve. If a head restraint guide sleeve is damaged, install a new one. Using a non-marring mallet, strike the top of the head restraint guide sleeve with moderate force, seating it in the backrest frame. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Page 7674 - Striking effort must be hard enough to snap the head restraint guide sleeve retainer in place in the backrest frame. 6. Inspect the head restraint guide sleeve. - Pull the head restraint guide sleeve out by hand, making sure it is locked in place. If the head restraint guide sleeve can be removed by hand, repeat the installation procedure. If the head restraint guide sleeve can be removed again after installing a second time, install a new head restraint guide sleeve. 7. Repeat these steps for the head restraint guide sleeve on the opposite side. 8. After installation of 2 new head restraint guide sleeves, install the head restraint in the following sequence. 1. Position the head restraint rods to the head restraint guide sleeve holes. 2. Push the head restraint down, guiding the rods into the head restraint guide sleeve holes. 3. Make sure the head restraint adjusts without excessive effort and locks in place. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7679 Memory Positioning Module: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7680 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7681 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7682 Memory Positioning Module: Service and Repair Driver Seat Module (DSM) Removal and Installation NOTICE: 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 Driver Seat Module (DSM) after installation. 1. NOTE: This step is necessary only if the DSM is being replaced. Upload the module configuration information from the DSM. 2. Remove the driver seat. 3. Remove the 2 DSM screws. 4. Disconnect the electrical connectors and remove the DSM. 5. NOTE: When a new DSM is installed, it is necessary to download the module configuration information from the scan tool into the new DSM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 7683 To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 7687 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 7692 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 7693 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 7694 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Third Row Folding Seat Motor, Left > Page 7695 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 7698 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 7699 Power Seat Motor: Diagrams Power Seat Motor Assembly, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 7700 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 7701 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Recliner Motor > Page 7702 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front Power Seat Motor: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7705 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7706 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7707 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7708 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7709 Power Seat Motor: Service and Repair Seat Recliner Motor Seat Recliner Motor Removal 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 3. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 4. NOTICE: 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. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so will cause the inboard and outboard recliners to become out of synchronization. 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 All seats 1. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so will cause the inboard and outboard recliners to become out of synchronization. Install the recliner motor in the following sequence. 1. Position the recliner shaft through the recliner motor and inboard recliner. - Slight turning of the recliner shaft may be necessary. 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 engage 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. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 5. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7710 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. For additional information, refer to Seat - Third Row See: Service and Repair/Third Row Seating/Seat - Third Row. 3. From under the RH seat, remove the 2 cushion pivot link assembly-to-cushion frame nuts. - To install, tighten to 22 Nm (16 lb-ft). 4. Remove the 2 latch-to-floor mounting bracket nuts and separate the RH seat and power latch 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. If unable to position the seat to access the bolt, use a suitable tool to remove the bolt. - To install, tighten to 25 Nm (18 lb-ft). 6. Remove the 2 bolts and latch cover. 7. On the side with the motor being serviced, release the backrest trim cover lower J-clip, side retainer and invert the cover up to access to 2 latch-to-backrest frame bolts. 8. 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 9. 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 10. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left Power Seat Relay: Locations Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 7715 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 7716 Power Seat Relay: Locations Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Locations > Third Row Folding Seat Relay, Left > Page 7717 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Diagrams > Third Row Folding Seat Relay, Left > Page 7720 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 7723 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 7724 Power Seat Relay: Testing and Inspection Third Row Folding Seat Relay, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Relay > Component Information > Testing and Inspection > Third Row Folding Seat Relay, Left > Page 7725 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left Power Seat Switch: Locations Third Row Folding Seat Switch, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7730 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7731 Power Seat Switch: Locations Third Row Folding Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7732 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7733 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7734 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7737 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7738 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7739 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7740 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7743 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7744 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7745 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7746 Power Seat Switch: Testing and Inspection Power Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and Inspection > Power Seat Switch, Left - 6-Way Power Seat > Page 7747 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front Power Seat Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7750 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7751 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7752 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7753 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7754 Power Seat Switch: Service and Repair Memory Set Switch 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7755 Power Seat Switch: Service and Repair Seat Control Switch Seat Control Switch Removal and Installation All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the cushion side shield in the following sequence. 1. Remove the clip and manual recline handle (if equipped). 2. Pull and remove the manual lumbar control knob (if equipped). 3. Remove the scrivet. 4. Remove the retention bracket screw and the retention bracket (if equipped). 5. Release the cushion side shield front clip. 6. From under the cushion side shield, release the 3 hook retainers. 7. Pull out on the cushion side shield at the back and release the pin-type retainer. 8. Separate the cushion trim cover elastic strap from the cushion side shield. 9. 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. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7756 Power Seat Switch: Service and Repair Seat Control Switch - Third Row Seat Control Switch - Third Row Removal and Installation NOTE: The third row seat control switches are located in the LH quarter trim panel. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement Seat Back: Removal and Replacement Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7761 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7762 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7763 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7764 1. For additional information, refer to the procedures. Seat Backrest - Front Seat Backrest - Front Removal and Installation NOTE: Driver shown, passenger similar. All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the cushion side shield in the following sequence. 1. Remove the clip and manual recline handle (if equipped). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7765 2. Pull and remove the manual lumbar control knob (if equipped). - Make sure the lumbar is completely relaxed before removing the handle. 3. Remove the scrivet. 4. Remove the retention bracket screw and the retention bracket (if equipped). 5. Release the cushion side shield front clip. 6. From under the cushion side shield, release the 3 hook retainers. 7. Pull out on the cushion side shield at the back and release the pin-type retainer. 8. Separate the cushion trim cover elastic strap from the cushion side shield. - With manual seat track, remove the cushion side shield. 9. With power seat track, 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 11. Disconnect the backrest power feed electrical connector and route out the wire harness. - Release any wire harness retainers. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7766 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 shown, passenger similar. Release the side air bag wire harness pin-type retainers across the back of the cushion frame. 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. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 18. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Seat - Exploded View, Second Row Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7767 Seat - Exploded View, Second Row 60 Percent E-Z Entry Backrest 60 Percent, E-Z Entry Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7768 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7769 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7770 40 Percent, E-Z Entry Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7771 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7772 Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7773 Bucket, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7774 Explorer/Mountaineer, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7775 Explorer Sport Trac, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7776 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7777 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7778 Second Row, 40 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7779 1. For additional information, refer to the procedures. Seat Backrest - Second Row, 40 Percent E-Z Entry Seat Backrest - Second Row, 40 Percent E-Z Entry Removal 1. Remove the second row, 40 percent E-Z entry seat from the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 2. NOTICE: 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 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7780 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: Use care when the seat back frame is removed and when releasing the recliners from a backrest upright position. The recliners are spring-loaded, which may cause the recliner upper arms to fold with significant speed/force. Failure to follow this instruction may result in serious personal injury. Position the inboard recliner pin to the recliner stop. The recliner pin must contact the inboard recliner outer plate (stop). 4. WARNING: Use care when the seat back frame is removed and when releasing the recliners from a backrest upright position. The recliners are spring-loaded, which may cause the recliner upper arms to fold with significant speed/force. Failure to follow this instruction may result in serious personal injury. NOTE: If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock in position. NOTE: 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. NOTICE: 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). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7781 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. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 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 Removal 1. Remove the second row, 60 percent E-Z entry seat from the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 2. NOTICE: 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 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7782 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: Use care when the seat back frame is removed and when releasing the recliners from a backrest upright position. The recliners are spring-loaded, which may cause the recliner upper arms to fold with significant speed/force. Failure to follow this instruction may result in serious personal injury. NOTE: An assistant will be necessary for this procedure. NOTE: If the latch feet are not locked around the strikers on the mounting plate, the recliners will not lock in position. NOTE: 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. 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. NOTICE: 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). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7783 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. 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. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 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 Removal 1. Release the seat backrest J-clip. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7784 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. 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 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 2 backrest support panel lower screws. 5. NOTICE: 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. 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 Removal All vehicles 1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information, refer to Seat - Second Row, Sport Trac See: Service and Repair/Second Row Seating/Seat - Second Row or Seat - Second Row, Explorer, 60/40 Bench . Sport Trac vehicles 2. Remove the safety belt guide cover in the following sequence. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7785 1. Pull out at the bottom and release the 2 safety belt guide cover retainers. 2. Tip the bottom of the safety belt guide cover up to release the top retainer and remove the safety belt guide cover. 3. Remove the retainers and the upper latch cover. All vehicles 4. Remove the safety belt anchor bolt. 5. Release the backrest trim cover lower J-clips. 6. Remove all the staples holding the backrest trim cover to the backrest support panel. 7. Position the backrest trim cover and foam pad to access the latch cover screws. 8. Remove the latch covers in the following sequence. 1. Remove the 4 latch cover screws. 2. Detach the backrest trim cover from the latch covers. 3. Remove the latch covers. Explorer and Mountaineer vehicles 9. Remove the 2 backrest support panel lower screws and detach the latch release cable from the backrest support panel. Sport Trac vehicles 10. NOTICE: Use care when separating the backrest 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 and invert the backrest trim cover. Pull the backrest trim cover up over the top of the backrest frame to expose the backrest support panel screws and the upper latch bolts. 11. Remove the backrest support panel in the following sequence. 1. Remove the backrest support panel screws. 2. Slide the backrest support panel down and release it from the safety belt retractor cover. 3. Release the latch release cable from the backrest support panel. 4. Remove the backrest support panel. 12. Remove the screw and the inner latch cover. 13. Remove the 2 upper latch bolts. 14. Separate the latch release cable pin-type retainer from the backrest frame. All vehicles 15. Remove the outboard upper pivot latch bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7786 16. Remove the 2 inboard and 2 outboard latch-to-backrest frame bolts. 17. Remove the 60 percent backrest. - For Explorer and Mountaineer, position the latch release cable out from between the backrest frame and backrest support panel. Installation Sport Trac vehicles 1. Install the backrest frame to the inboard and outboard latches in the following sequence. 1. Position the backrest frame to the inboard and outboard latches and hand-start the 2 inboard and 2 outboard latch-to-backrest frame bolts. 2. Hand-start the outboard upper pivot latch bolt. 3. Install the 2 inboard latch-to-backrest frame bolts. - Tighten to 40 Nm (30 lb-ft). 4. Install the 2 outboard latch-to-backrest frame bolts. - Tighten to 40 Nm (30 lb-ft). 5. Install the outboard upper pivot latch bolt. - Tighten to 40 Nm (30 lb-ft). 2. Position the upper latch and install the bolts. - Tighten to 25 Nm (18 lb-ft). 3. Position the inner latch cover and install the screw. 4. NOTE: The safety belt retractor has been removed for clarity. Position the backrest support panel to the backrest frame and route the latch release cable. - The latch release cable is to pass between the backrest frame and the backrest support at the 2 points shown. 5. NOTE: The cable is to move freely after assembly. Install the backrest support panel screws to the backrest frame. - Attach the latch release cable to the backrest support panel. Explorer and Mountaineer vehicles 6. NOTE: The cable is to move freely after assembly. Position the backrest to the inboard and outboard latches and route the cable between the backrest frame and support panel. - The cable is to pass between the backrest frame and the backrest support at the 2 points shown. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7787 7. Install the backrest frame to the inboard and outboard latches in the following sequence. 1. Position the backrest frame to the inboard and outboard latches and hand-start the 2 inboard and 2 outboard latch-to-backrest frame bolts. 2. Hand-start the outboard upper pivot latch bolt. 3. Install the 2 inboard latch-to-backrest frame bolts. - Tighten to 40 Nm (30 lb-ft). 4. Install the 2 outboard latch-to-backrest frame bolts. - Tighten to 40 Nm (30 lb-ft). 5. Install the outboard upper pivot latch bolt. - Tighten to 40 Nm (30 lb-ft). 8. NOTE: The cable is to move freely after assembly. Install the backrest support panel screws to the backrest frame. - Attach the latch release cable to the backrest support panel. 9. Route the latch release cable through the inboard latch holder. All vehicles 10. Position the latch release cable in front of the spring. 11. Roll the backrest trim cover down. - For Sport Trac, route the safety belt through the backrest trim cover. - Attach the backrest trim cover to backrest foam pad hook-and-loop strips. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7788 12. Attach the backrest trim cover to both of the latch covers. Position the 2 latch covers and install the 4 screws. 13. Position the trim cover and install staples in the backrest support panel. 14. Attach the backrest trim cover J-clip. 15. Position the safety belt anchor and install the bolt. - To install, tighten to 121 Nm (89 lb-ft). Sport Trac vehicles 16. Position the upper latch cover and install the retainers. 17. Install the safety belt guide cover. All vehicles 18. Install the second row 60 percent seat of the 60/40 bench seat. For additional information, refer to Seat - Second Row, Sport Trac See: Service and Repair/Second Row Seating/Seat - Second Row or Seat - Second Row, Explorer, 60/40 Bench . Seat Backrest - Second Row, Bucket Seat Backrest - Second Row, Bucket 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. Seat Recliner - Second Row, 40 Percent E-Z Entry Seat Recliner - Second Row, 40 Percent E-Z Entry Removal and Installation WARNING: Use care when the seat back frame is removed and when releasing the recliners from a backrest upright position. The recliners are spring-loaded, which may cause the recliner upper arms to fold with significant speed/force. Failure to follow this instruction may result in serious personal injury. NOTICE: The recliner bolts must be tightened in sequence or recliner latches that do not lock in place or binding may occur. Inboard and/or outboard recliners 1. Remove the second row, 40 percent E-Z entry seat from the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 2. Remove the second row, 40 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 40 Percent E-Z Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40 Percent E-Z Entry. Outboard recliner 3. Remove 3 screws, recliner handle and outboard recliner outer cover. 4. Separate the outboard recliner. - Remove the 2 outboard recliner-to-cushion frame bolts. - NOTE: When pulling outboard recliner out, note keyed position of recliner release shaft as it may pull out of inboard recliner. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7789 Pull out to release the outboard recliner from the recliner release shaft. - Separate the outboard recliner. 5. Remove the outboard recliner inner cover. 6. 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. Inboard recliner 7. Remove the 2 screws and inboard recliner outer cover. 8. Separate the inboard recliner. - Remove the 2 inboard recliner-to-cushion frame bolts and the safety belt buckle. - NOTE: When pulling the inboard recliner out, note keyed position of recliner release shaft as it may pull out of outboard recliner. Pull out to release the inboard recliner from the recliner release shaft. - Separate the inboard recliner. 9. Remove the inboard recliner inner cover. 10. Remove the screw and separate the kneeling mechanism release cable pivot at the inboard recliner. - Remove the inboard recliner. Installation Inboard and/or outboard recliners 1. If necessary, position the recliner release shaft onto the recliner release pivot stub of the recliner still attached to the seat. Inboard recliner 2. Install the inboard recliner inner cover. 3. NOTE: The inboard recliner inner cover is removed for clarity. Position the inboard recliner release pivot stub into the recliner shaft. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7790 4. Install the 2 inboard recliner-to-cushion frame bolts. - Tighten to 55 Nm (41 lb-ft). 5. Position the kneeling mechanism release cable pivot onto the inboard recliner and install the screw. - Make sure to put the recliner pin through the cable pivot. Outboard recliner 6. NOTE: The cable ends are color coded/keyed to the levers. Position each keyed cable end to the outboard recliner lever and rotate into position. - Install the cable casing to the outboard recliner. 7. Install the outboard recliner inner cover. 8. NOTE: The outboard recliner inner cover is removed for clarity. Position the outboard recliner release pivot stub into the recliner shaft. 9. Install the 2 outboard recliner-to-cushion frame bolts. - Tighten to 55 Nm (41 lb-ft). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7791 Inboard and/or outboard recliners 10. Install the second row, 40 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 40 Percent E-Z Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40 Percent E-Z Entry. 11. Install the second row, 40 percent E-Z entry seat into the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 12. 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 Recliner - Inboard, Second Row, 60 Percent E-Z Entry Seat Recliner - Inboard, Second Row, 60 Percent E-Z Entry Removal 1. Remove the second row, 60 percent E-Z entry seat from the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 2. Remove the second row, 60 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 60 Percent, E-Z Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry. 3. Separate the kneeling mechanism release cable pivot at the inboard recliner. 4. Release the cushion trim cover at the inboard side of the cushion frame. Pull the cushion trim cover back to expose 4 inboard recliner bolts. 5. Remove the inboard recliner. - Remove the 2 inboard recliner-to-cushion frame bolts. - Remove the inboard recliner-to-kneeling mechanism bolt. - Remove the inboard recliner-to-latch feet assembly bolt. - NOTE: When pulling inboard recliner out, note keyed position of recliner release shaft as it may pull out of outboard recliner. Pull out and remove the inboard recliner. - Remove the inboard recliner inner cover. Installation 1. If necessary, position the recliner release shaft onto the outboard recliner release pivot stub. 2. Install the inboard recliner inner cover. 3. NOTE: The inboard recliner inner cover has been removed for clarity. Position the inboard recliner. - Position the inboard recliner release pivot stub into the recliner release shaft. - Align the inboard recliner to the cushion frame, latch feet assembly and kneeling mechanism. 4. Hand-start the 2 inboard recliner-to-cushion frame bolts, inboard recliner-to-latch feet assembly bolt and inboard recliner-to-kneeling mechanism bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7792 5. NOTICE: The recliner bolts must be tightened in sequence or recliner latches that do not lock in place or binding may occur. Install the inboard recliner bolts in the following sequence. 1. Install the inboard recliner-to-latch feet assembly bolt. - Tighten to 55 Nm (41 lb-ft). 2. Install the inboard recliner-to-kneeling mechanism bolt. - Tighten to 55 Nm (41 lb-ft). 3. Install the inboard recliner-to-cushion frame rear bolt. - Tighten to 55 Nm (41 lb-ft). 4. Install the inboard recliner-to-cushion frame front bolt. - Tighten to 55 Nm (41 lb-ft). 6. Position the kneeling mechanism release cable pivot at the inboard recliner. - Make sure the inboard recliner pin is through the cable pivot. 7. Attach the cushion trim cover retainers at the inboard side of the cushion frame. 8. Install the second row, 60 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 60 Percent, E-Z Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry. 9. Install the second row, 60 percent E-Z entry seat into the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 10. 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 Recliner - Outboard, Second Row, 60 Percent E-Z Entry Seat Recliner - Outboard, Second Row, 60 Percent E-Z Entry Removal 1. Remove the second row, 60 percent E-Z entry seat from the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 2. Remove the second row, 60 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 60 Percent, E-Z Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry. 3. Remove 3 screws, recliner handle and outboard recliner outer cover. 4. Remove the 2 outboard recliner-to-backrest frame bolts. 5. NOTE: When pulling outboard recliner out, note keyed position of recliner release shaft as it may pull out of inboard recliner. Remove 2 outboard recliner-to-cushion frame bolts, pull out and separate the outboard recliner. 6. Remove the outboard recliner inner cover. 7. Remove the outboard recliner. 1. Rotate the cable casing out of the outboard recliner. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7793 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. Installation 1. If necessary, position the recliner release shaft onto the inboard recliner release pivot stub. 2. NOTE: The cable ends are color coded/keyed to the levers. Position each keyed cable end to the outboard recliner lever and rotate into position. - Install the cable casing to the outboard recliner. 3. Install the outboard recliner inner cover. 4. Position the outboard recliner release pivot stub into the recliner shaft. 5. Install the 2 outboard recliner-to-cushion frame bolts. - Tighten to 55 Nm (41 lb-ft). 6. Install the second row, 60 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 60 Percent, E-Z Entry See: Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry. 7. Install the second row, 60 percent E-Z entry seat into the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 8. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7794 Seat - Exploded View, Third Row Seat - Exploded View, Third Row Third Row Seat Backrest NOTE: RH backrest shown, LH similar. NOTE: Power latch shown, manual latch similar. Third Row Seat Cushion NOTE: RH cushion shown, LH similar. NOTE: Power latch shown, manual latch similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7795 1. For additional information, refer to the procedures. Seat Backrest - Third Row Seat Backrest - Third Row 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7796 4. Release the backrest trim cover lower J-clip on the backrest being serviced. 5. NOTICE: Use care when separating the backrest 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7797 Seat Back: Overhaul Front Seats Seat Backrest - Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Disassembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7798 WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. 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. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before releasing the vehicle to the customer. NOTE: The manual recliners and power recliners are serviced as part of the backrest frame. All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See: Removal and Replacement/Front Seats/Seat Backrest - Front. 3. Remove the 2 head restraint guide sleeves. For additional information, refer to Head Restraint Guide Sleeve See: Head Rest/Service and Repair. 4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 5. NOTICE: 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. Remove the backrest trim cover. Heated seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7799 9. 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 10. Separate the backrest foam pad from the backrest frame. 11. 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 12. Release the 2 manual lumbar spring clips from the backrest frame and remove the manual lumbar. Seat with power lumbar 13. Remove the power lumbar adjust assembly in the following sequence. 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. Seat with power recline 14. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so will cause the inboard and outboard recliners to become out of synchronization. Remove a one-way push clip from the recliner shaft and remove the recliner shaft. 15. Disconnect the electrical connector, remove the screw and the power recline motor. Assembly Seat with power recline 1. NOTICE: Do not rotate the recliner shaft while not engaged to both recliners. Failure to do so will cause the inboard and outboard recliners to become out of synchronization. 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7800 3. Attach the 2 manual lumbar spring clips to the backrest frame. All seats 4. WARNING: Before installing the seat side air bag module/deployment chute assembly: - Inspect the side air bag module and mounting surfaces for any damage or foreign material. - Remove any foreign material from the mounting surfaces of the deployment chute, the seat backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad. - Install new parts if damaged. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if the air bag material has been exposed, install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash. WARNING: Inspect the seat side air bag module cavity in the seat backrest foam pad for any foreign material. If any foreign material is found, remove it. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increases the risk of serious personal injury or death in a crash. NOTICE: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. Failure to follow this instruction may result in wiring harness damage. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7801 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. Install the 2 head restraint guide sleeves. For additional information, refer to Head Restraint Guide Sleeve See: Head Rest/Service and Repair. 15. Install the front seat backrest. For additional information, refer to Seat Backrest - Front See: Removal and Replacement/Front Seats/Seat Backrest - Front. 16. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 17. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7802 Disassembly and Assembly 1. Remove the second row, 40 percent E-Z entry seat from the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 2. Remove the second row, 40 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 40 Percent E-Z Entry See: Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40 Percent E-Z Entry. 3. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 4. NOTICE: Use care when separating the backrest 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7803 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 Second Row, 60 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7804 Disassembly 1. Remove the second row, 60 percent E-Z entry seat. For additional information, refer to Seat Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. 2. Remove the second row, 60 percent E-Z entry seat backrest. For additional information, refer to Seat Backrest - Second Row, 60 Percent, E-Z Entry See: Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, E-Z Entry. 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. NOTICE: Use care when separating the backrest 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7805 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 Disassembly and Assembly Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7806 1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information, refer to Seat - Second Row, Sport Trac See: Service and Repair/Second Row Seating/Seat - Second Row or Seat - Second Row, Explorer, 60/40 Bench . 2. Remove the second row, 40 percent seat backrest. For additional information, refer to Seat Backrest - Second Row, 40 Percent, Bench See: Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40 Percent, Bench. 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. NOTE: 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. NOTICE: Use care when separating the backrest 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. NOTICE: 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 Explorer/Mountaineer, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7807 Explorer Sport Trac, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7808 Disassembly and Assembly 1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information, refer to Seat - Second Row, Sport Trac See: Service and Repair/Second Row Seating/Seat - Second Row or Seat - Second Row, Explorer, 60/40 Bench . 2. Remove the second row, 60 percent seat backrest. For additional information, refer to Seat Backrest - Second Row, 60 Percent, Bench See: Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 60 Percent, Bench. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7809 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. NOTE: 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. For Explorer and Mountaineer, pull at the bottom and remove the safety belt guide cover. 6. NOTICE: Use care when separating the backrest 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 and 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. Remove the seat tether-to-riser frame nut and the seat tether (if equipped). - To install, tighten to 55 Nm (41 lb-ft). 11. Remove the screw and the release handle. 12. Remove the 3 screws and the outboard latch cover. 13. Remove the outboard latch-to-riser frame bolts. - To install, tighten to 40 Nm (30 lb-ft). For Sport Trac, remove the outboard and upper latch assembly. 14. NOTICE: For Explorer and Mountaineer, 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 inboard latch-to-riser frame front bolt. For Explorer and Mountaineer, remove the latch assembly. For Sport Trac, remove the inboard latch. - To install, tighten to 121 Nm (89 lb-ft). 15. To assemble, reverse the disassembly procedure. Seat Backrest - Second Row, Bucket Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7810 Seat Backrest - Second Row, Bucket Disassembly and Assembly 1. Remove the second row, 40 percent bucket seat backrest. For additional information, refer to Seat Backrest - Second Row, Bucket See: Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, Bucket. 2. Remove the head restraint. 3. NOTICE: Use care when separating the backrest 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. NOTE: 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. 7. To assemble, reverse the disassembly procedure. Third Row Seating Seat Backrest - Third Row Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7811 Third Row Seat Backrest NOTE: RH backrest shown, LH similar. Disassembly and Assembly All seats 1. Remove the seat backrest. For additional information, refer to Seat Backrest - Third Row See: Removal and Replacement/Third Row Seating/Seat Backrest - Third Row. 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). Manual fold seats 4. Release the 3 backrest release handle clips and separate from the backrest. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Removal and Replacement > Page 7812 All seats 5. NOTICE: Use care when separating the backrest 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats Seat Cover: Service and Repair Front Seats Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7817 Driver Seat Cushion NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7818 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7819 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7820 1. For additional information, refer to the procedures. Seat Backrest Cover - Front Seat Backrest Cover - Front Removal and Installation WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side air bag module deploying incorrectly and increase the risk of serious personal injury or death in a crash. All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7821 3. Remove the 2 head restraint guide sleeves. For additional information, refer to Head Restraint Guide Sleeve See: Head Rest/Service and Repair. 4. Remove the plastic rivets attaching the backrest trim cover to the inboard and outboard recliners. 5. NOTICE: 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. Remove the backrest trim cover. 9. To install, reverse the removal procedure. 10. Install the front seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 11. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 12. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Seat Cushion Cover - Front Seat Cushion Cover - Front Removal and Installation All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the cushion side shield in the following sequence. 1. Remove the clip and manual recline handle (if equipped). 2. Pull and remove the manual lumbar control knob (if equipped). 3. Remove the scrivet. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7822 4. Remove the retention bracket screw and the retention bracket (if equipped). 5. Release the cushion side shield front clip. 6. From under the cushion side shield, release the 3 hook retainers. 7. Pull out on the cushion side shield at the back and release the pin-type retainer. 8. Separate the cushion trim cover elastic strap from the cushion side shield. - With manual seat track, remove the cushion side shield. 9. With power seat track, 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. NOTICE: 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. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 7. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7823 Seat Cover: Service and Repair Second Row Seating Seat - Exploded View, Second Row Seat - Exploded View, Second Row 60 Percent E-Z Entry Backrest 60 Percent, E-Z Entry Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7824 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7825 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7826 40 Percent, E-Z Entry Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7827 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7828 Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7829 Bucket, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7830 Explorer/Mountaineer, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7831 Explorer Sport Trac, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7832 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7833 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7834 Second Row, 40 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7835 1. For additional information, refer to the procedures. Seat Backrest Cover - Second Row, Bucket Seat Backrest Cover - Second Row, Bucket Removal and Installation 1. Remove the head restraint. 2. NOTICE: Use care when separating the backrest 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, separate the hook-and-loop fasteners, remove 2 rows of hog rings and invert the backrest trim cover as high as it will go. 3. NOTE: The inboard and outboard head restraint sleeves are not interchangeable. NOTE: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7836 4. Remove the seat backrest trim cover. 5. To install, reverse the removal procedure. Seat Backrest Cover - Second Row, 40 Percent E-Z Entry Seat Backrest Cover - Second Row, 40 Percent E-Z Entry Removal and Installation 1. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 2. NOTICE: 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. NOTICE: 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, 40 Percent, Bench Seat Backrest Cover - Second Row, 40 Percent, Bench Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7837 Removal and Installation 1. Remove the head restraint. 2. Release the seat backrest J-clip. 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. NOTE: 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. NOTICE: Use care when separating the seat backrest 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. 7. To install, reverse the removal procedure. Seat Backrest Cover - Second Row, 60 Percent, Bench Seat Backrest Cover - Second Row, 60 Percent, Bench Removal and Installation All vehicles 1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information, refer to Seat - Second Row, Sport Trac See: Service and Repair/Second Row Seating/Seat - Second Row or Seat - Second Row, Explorer, 60/40 Bench . 2. Using an appropriate tool, push in the hole of each head restraint guide while lifting up and remove the head restraint. 3. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. Remove the safety belt anchor bolt. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7838 - To install, tighten to 121 Nm (89 lb-ft). 4. Remove the safety belt guide cover in the following sequence. 1. Pull out at the bottom and release the 2 safety belt guide cover retainers. 2. Tip the bottom of the safety belt guide cover up to release the top retainer and remove the safety belt guide cover. Sport Trac vehicles 5. Remove the retainers and the upper latch cover. All vehicles 6. Release the backrest trim cover J-clip. 7. Remove all the staples in the backrest support panel. 8. Reposition the backrest trim cover and foam pad to access the latch cover screws. 9. Remove the latch covers in the following sequence. 1. Remove the 4 latch cover screws. 2. Detach the backrest trim cover from the latch covers. 3. Remove the latch covers. 10. NOTICE: Use care when separating the backrest 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 and invert the backrest trim cover. 11. NOTE: The inboard and outboard head restraint sleeves are not interchangeable. NOTE: 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. 12. Remove the backrest trim cover. - Feed the safety belt out through the opening in the backrest trim cover. 13. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7839 Removal 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. NOTICE: Make sure the safety belt webbing is not twisted prior to installation. Failure to follow this instruction may result in incorrect operation of the safety belt retractor. 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. NOTICE: 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. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, Bucket Seat Cushion Cover - Second Row, Bucket Removal and Installation 1. NOTICE: 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 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7840 2. Release the cable from the seat riser and remove the cushion trim cover. 3. 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 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. NOTICE: 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 remove the cushion trim cover from the cushion foam pad. 4. To install, reverse the removal procedure. - Make sure the lower anchor and tethers for children wires at the rear of the cushion frame are positioned through the cushion trim cover and accessible for use after installation. Seat Cushion Cover - Second Row, 40 Percent, Bench Seat Cushion Cover - Second Row, 40 Percent, Bench Removal and Installation 1. Remove the second row 40 percent seat of the 60/40 bench seat. For additional information, refer to Seat - Second Row, Sport Trac See: Service and Repair/Second Row Seating/Seat - Second Row or Seat - Second Row, Explorer, 60/40 Bench . 2. NOTICE: 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. 3. To install, reverse the removal procedure. Seat Cushion Cover - Second Row, 60 Percent, Bench Seat Cushion Cover - Second Row, 60 Percent, Bench Removal and Installation 1. Remove the second row 60 percent seat of the 60/40 bench seat. For additional information, refer to Seat - Second Row, Sport Trac See: Service and Repair/Second Row Seating/Seat - Second Row or Seat - Second Row, Explorer, 60/40 Bench . 2. NOTICE: 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. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7841 Seat Cushion Cover - Second Row, 60 Percent, E-Z Entry Seat Cushion Cover - Second Row, 60 Percent, E-Z Entry Removal 1. Remove the 2 screws and the latch feet release bar. 2. Release all the cushion trim cover retainers and pin-type retainers. 3. NOTICE: 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. 4. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and buckles are accessible to the occupants. To install, reverse the removal procedure. - Make sure the lower anchor and tethers for children wires at the rear of the cushion frame are positioned through the cushion trim cover and accessible for use after installation. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7842 Seat Cover: Service and Repair Third Row Seating Seat - Exploded View, Third Row Seat - Exploded View, Third Row Third Row Seat Backrest NOTE: RH backrest shown, LH similar. NOTE: Power latch shown, manual latch similar. Third Row Seat Cushion NOTE: RH cushion shown, LH similar. NOTE: Power latch shown, manual latch similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7843 1. For additional information, refer to the procedures. Seat Backrest Cover - Third Row Seat Backrest Cover - Third Row 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). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seats > Page 7844 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. NOTICE: Use care when separating the backrest 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 Removal and Installation 1. Remove the third row seat from the vehicle. For additional information, refer to Seat - Third Row See: Service and Repair/Third Row Seating/Seat - Third Row. 2. Release the cushion trim cover retainers attached to the bottom of the cushion frame. 3. NOTICE: 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. 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 (V6-4.0L (2009)) 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 Removal and Installation 1. Position the backrest to the upright position. 2. Remove the third row seat from the vehicle. For additional information, refer to Seat - Third Row See: Service and Repair/Third Row Seating/Seat - Third Row. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7849 Seat Cushion: Overhaul Front Seats Seat Cushion - Front Driver Seat Cushion NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7850 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7851 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7852 Disassembly and Assembly All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 2. Remove the seat track. For additional information, refer to Seat Track See: Seat Track/Service and Repair/Seat Track. 3. Remove the front seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 4. NOTICE: 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 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7853 All seats 6. To assemble, reverse the disassembly procedure. 7. Install the front seat backrest. For additional information, refer to Seat Backrest - Front See: Seat Back/Service and Repair/Removal and Replacement/Front Seats/Seat Backrest - Front. 8. Install the seat track. For additional information, refer to Seat Track See: Seat Track/Service and Repair/Seat Track. 9. Install the front seat. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 10. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Seat Cushion - Second Row, 40 Percent E-Z Entry Seat Cushion - Second Row, 40 Percent E-Z Entry Second Row, 40 Percent, E-Z Entry Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7854 Disassembly 1. Remove the second row 40 percent E-Z entry seat from the vehicle. For additional information, refer to Seat - Second Row, 60/40, E-Z Entry See: Service and Repair/Second Row Seating/Seat - Second Row, 60/40, E-Z Entry. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7855 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. 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. For additional information, refer to Seat Backrest - Second Row, 40 Percent E-Z Entry See: Seat Back/Service and Repair/Removal and Replacement/Second Row Seating/Seat Backrest/Seat Backrest - Second Row, 40 Percent E-Z Entry. 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. NOTICE: 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Replacement > Page 7856 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7861 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7862 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7863 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7864 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7865 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7866 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7867 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7868 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7869 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7870 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7871 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7875 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7876 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7877 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7878 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 Seat Heater: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 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 (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 7882 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7883 Seat Heater: Service and Repair Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion NOTE: Power seat track shown, manual seat track similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7884 NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7885 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7886 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 7887 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair Seat Heater Control Module: Service and Repair Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion NOTE: Power seat track shown, manual seat track similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Page 7891 NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Page 7892 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Page 7893 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Page 7894 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 7898 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 7901 Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 7902 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 7903 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 7904 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 7905 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating Seat Latch: Service and Repair Second Row Seating Seat - Exploded View, Second Row Seat - Exploded View, Second Row 60 Percent E-Z Entry Backrest 60 Percent, E-Z Entry Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7910 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7911 40 Percent E-Z Entry Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7912 40 Percent, E-Z Entry Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7913 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7914 Bucket, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7915 Bucket, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7916 Explorer/Mountaineer, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7917 Explorer Sport Trac, 60 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7918 Second Row, 60 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7919 Second Row, 40 Percent Bench, Backrest Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7920 Second Row, 40 Percent Bench, Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7921 1. For additional information, refer to the procedures. Seat Latch Striker - Second Row, 60 Percent Bench Seat Latch Striker - Second Row, Sport Trac, 60 Percent Bench Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7922 Removal and Installation 1. Fold the rear 60 percent and 40 percent seat backrests forward. 2. Remove the 2 screws from the storage compartment. 3. NOTE: When separating the cab rear trim panel, start in the upper left corner, moving clockwise and separate the panel from the retaining clips. Pull to release the clips and position the cab rear trim panel forward to access the seat latch striker. 4. Remove the 2 bolts and remove the striker. - To install, tighten to 30 Nm (22 lb-ft). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7923 Seat Latch: Service and Repair Third Row Seating Seat - Exploded View, Third Row Seat - Exploded View, Third Row Third Row Seat Backrest NOTE: RH backrest shown, LH similar. NOTE: Power latch shown, manual latch similar. Third Row Seat Cushion NOTE: RH cushion shown, LH similar. NOTE: Power latch shown, manual latch similar. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7924 1. For additional information, refer to the procedures. Seat Latch - Third Row, Manual 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7925 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. NOTICE: Use care when separating the backrest 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. NOTICE: Use care when separating the backrest 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). 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Second Row Seating > Page 7926 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track Seat Track: Service and Repair Seat Track Seat Track Removal and Installation All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Service and Repair/Front Seats/Seat - Front. 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. For additional information, refer to Occupant Classification Sensor (OCS) in the removal and installation portion of Air Bag Systems. Passenger seat not receiving a new seat track 4. NOTE: Note the position and the routing of the OCS 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 in the following sequence. 1. Remove the clip and manual recline handle (if equipped). 2. Pull and remove the manual lumbar control knob (if equipped). 3. Remove the scrivet. 4. Remove the retention bracket screw and the retention bracket (if equipped). 5. Release the cushion side shield front clip. 6. From under the cushion side shield, release the 3 hook retainers. 7. Pull out on the cushion side shield at the back and release the pin-type retainer. 8. Separate the cushion trim cover elastic strap from the cushion side shield. - With manual seat track, remove the cushion side shield. 9. With power seat track, remove the seat control switch knob and separate the seat control switch from the cushion side shield. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7931 - Remove the cushion side shield. Power seat 6. Separate the seat control switch wire harness pin-type retainer from the cushion frame. Driver seat 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 shown, driver 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7932 - 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. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Service and Repair/Front Seats/Seat - Front. Passenger seat 19. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7933 Seat Track: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7934 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7935 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7936 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Seat Track > Page 7937 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations > Page 7941 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 7946 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Door Lock Switch, Passenger Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7951 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Door Lock Switch, Driver Side Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7954 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7955 Power Door Lock Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7956 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7957 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. 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7961 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7962 Power Mirror Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7963 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7964 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7965 Power Mirror Switch: Service and Repair Exterior Mirror Control Switch Removal and Installation 1. Remove the front door trim panel. 2. Depress the 2 retaining tabs and 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left Power Seat Switch: Locations Third Row Folding Seat Switch, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7970 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7971 Power Seat Switch: Locations Third Row Folding Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7972 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7973 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Third Row Folding Seat Switch, Left > Page 7974 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left Power Seat Switch: Diagrams Power Seat Switch, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7977 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7978 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7979 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Power Seat Switch, Left > Page 7980 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 6-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7983 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7984 Power Seat Switch: Testing and Inspection Power Seat Switch, Left - 10-Way Power Seat Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7985 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7986 Power Seat Switch: Testing and Inspection Power Seat Switch, Right Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 7987 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front Power Seat Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7990 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7991 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7992 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7993 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7994 Power Seat Switch: Service and Repair Memory Set Switch 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7995 Power Seat Switch: Service and Repair Seat Control Switch Seat Control Switch Removal and Installation All seats 1. Remove the front seat. For additional information, refer to Seat - Front See: Seats/Service and Repair/Front Seats/Seat - Front. 2. Remove the cushion side shield in the following sequence. 1. Remove the clip and manual recline handle (if equipped). 2. Pull and remove the manual lumbar control knob (if equipped). 3. Remove the scrivet. 4. Remove the retention bracket screw and the retention bracket (if equipped). 5. Release the cushion side shield front clip. 6. From under the cushion side shield, release the 3 hook retainers. 7. Pull out on the cushion side shield at the back and release the pin-type retainer. 8. Separate the cushion trim cover elastic strap from the cushion side shield. 9. 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. If a passenger seat has been serviced, do not prove out the SRS at this time. For additional information, refer to Seat Front See: Seats/Service and Repair/Front Seats/Seat - Front. Passenger seat 6. Carry out the Occupant Classification Sensor (OCS) System Zero Seat Weight Test and prove out the SRS. For additional information, refer to General Procedures portion of Air Bag Systems. See: Restraint Systems/Air Bag Systems/Testing and Inspection/Component Tests and General Diagnostics Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Seat - Exploded View, Front > Page 7996 Power Seat Switch: Service and Repair Seat Control Switch - Third Row Seat Control Switch - Third Row Removal and Installation NOTE: The third row seat control switches are located in the LH quarter trim panel. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations Power Sliding Door Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 8000 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 8001 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 8002 Power Sliding Door Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 8003 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 8007 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 8008 Power Trunk / Liftgate Lock Switch: Service and Repair Liftgate Window Latch Actuator Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 8012 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 8015 Seat Heater Switch: Service and Repair Seat - Exploded View, Front Seat - Exploded View, Front Front Seat Backrest NOTE: Driver backrest shown, passenger backrest similar. Driver Seat Cushion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 8016 NOTE: Power seat track shown, manual seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 8017 Passenger Seat Cushion NOTE: Manual seat track shown, power seat track similar. NOTE: The retention bracket and screw can be used to repair cushion side shields that will not retain to the cushion frame wire. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 8018 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch > Page 8019 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 8023 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 8030 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation Sound Proofing / Insulation: Description and Operation Insulation Insulation Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the interior of the vehicle. Mastic insulators are also used as insulation. For information on the location of the mastic insulators, refer to Sound Deadeners and Insulators. See: Sound Deadeners and Insulators Insulation is installed: - under the hood. - in front of the instrument panel. - over and under the tunnel. - over the front and rear floor pans. - inside the B-, C- and D-pillars. - on the wheel house/quarter panel. - on the engine side dash insulator (behind the engine-car rearward). It has heat-bondable mastic deadeners for improved NVH characteristics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 8035 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and Operation > Insulation > Page 8036 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch Tailgate Latch: Service and Repair Tailgate Latch 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 8042 Tailgate Latch: Service and Repair Tailgate Handle, Lock and Latches - Exploded View Tailgate Handle, Lock and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 8043 Tailgate Latch: Service and Repair Tailgate Latch Remote Control 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Service and Repair Tailgate 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. NOTE: 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. For additional information, refer to Tailgate Release Handle See: Tailgate Release Handle/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Tailgate Release Handle Tailgate Release Handle: Service and Repair Tailgate Release Handle Tailgate Release Handle Removal and Installation 1. Remove the tailgate latch remote control. For additional information, refer to Tailgate Latch Remote Control See: Tailgate Latch/Service and Repair/Tailgate Latch Remote Control. 2. Remove the tailgate release handle. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Tailgate Release Handle > Page 8051 Tailgate Release Handle: Service and Repair Tailgate Handle, Lock and Latches - Exploded View Tailgate Handle, Lock and Latches - Exploded View 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Tonneau Cover Lock Cylinder Truck Bed Cover: Service and Repair Tonneau Cover Lock Cylinder Tonneau Cover Lock Cylinder Removal and Installation 1. Remove the tonneau cover latch release cable. For additional information, refer to Tonneau Cover Latch Release Cable See: Tonneau Cover Latch Release Cable. 2. Remove the tonneau cover lock cylinder. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Tonneau Cover Lock Cylinder > Page 8057 Truck Bed Cover: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Component Information > Service and Repair > Tonneau Cover Lock Cylinder > Page 8058 Truck Bed Cover: 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. For additional information, refer to Tonneau Cover Latch See: Tonneau Cover Latch. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Door / Cover > Component Information > Service and Repair > Pickup Bed Storage Compartment Lid - Front Compartment Truck Bed Storage Compartment Door / Cover: Service and Repair Pickup Bed Storage Compartment Lid - Front Compartment Pickup Bed Storage Compartment Lid - Front Compartment 1. Open the storage compartment lid and disconnect the compartment lid struts from the door. 2. Remove the 6 storage compartment lid nuts. - To install, tighten to 12 Nm (106 lb-in). 3. Remove the storage compartment lid. 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Truck Bed Storage Compartment Door / Cover > Component Information > Service and Repair > Pickup Bed Storage Compartment Lid - Front Compartment > Page 8064 Truck Bed Storage Compartment Door / Cover: Service and Repair Pickup Bed Storage Compartment Lid - Side Compartment Pickup Bed Storage Compartment Lid - Side Compartment 1. Open the compartment lid and remove the pickup bed seal. 2. Remove the storage compartment door. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (106 lb-in). 2. NOTICE: 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. For additional information, refer to Pickup Bed Storage Compartment Latch See: Truck Bed Storage Compartment Latch/Service and Repair. 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 (V6-4.0L (2009)) 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 1. Remove the side compartment lid. For additional information, refer to Pickup Bed Storage Compartment Lid - Side Compartment See: Truck Bed Storage Compartment Door / Cover/Service and Repair/Pickup Bed Storage Compartment Lid Side Compartment. 2. NOTE: The side compartment hinge is installed prior to the storage compartment seal. NOTE: 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 (V6-4.0L (2009)) 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 8072 Truck Bed Storage Compartment Hinge: Service and Repair Pickup Bed Storage Compartment Hinge - Front Compartment Pickup Bed Storage Compartment Hinge - Front Compartment 1. Remove the front compartment lid. For additional information, refer to Pickup Bed Storage Compartment Lid - Front Compartment See: Truck Bed Storage Compartment Door / Cover/Service and Repair/Pickup Bed Storage Compartment Lid - Front Compartment. 2. Remove the pickup bed. For additional information, refer to Pickup Bed See: Service and Repair. 3. Remove the front compartment lid hinge nuts from the front of the pickup bed. - To install, tighten to 12 Nm (106 lb-in). 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 (V6-4.0L (2009)) 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 (106 lb-in). 2. NOTICE: 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 (V6-4.0L (2009)) 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 1. Remove the side compartment lid. For additional information, refer to Pickup Bed Storage Compartment Lid - Side Compartment See: Truck Bed Storage Compartment Door / Cover/Service and Repair/Pickup Bed Storage Compartment Lid Side Compartment. 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 (V6-4.0L (2009)) 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 8080 Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage Compartment Seal - Front Compartment Pickup Bed Storage Compartment Seal - Front Compartment 1. Remove the front compartment lid. For additional information, refer to Pickup Bed Storage Compartment Lid - Front Compartment See: Truck Bed Storage Compartment Door / Cover/Service and Repair/Pickup Bed Storage Compartment Lid - Front Compartment. 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 (V6-4.0L (2009)) 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. NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8091 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation NOTE: For LH front only, the front window motor must be initialized whenever the front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run. 1. Remove the front door window glass. For additional information, refer to Window Glass - Front Door See: Doors, Hood and Trunk/Doors/Front Door/Front Door Window Glass/Service and Repair/Window Glass - Front Door. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (106 lb-in). 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. - For LH front window only, initialize the LH front window motor. For additional information, refer to Window Motor Initialization - Front See: Windows and Glass/Windows/Service and Repair/Window Motor Initialization - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear Door Glass Top Run - Rear Removal and Installation 1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear Door See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Window Glass/Service and Repair/Window Glass - Rear Door. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (106 lb-in). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear > Page 8096 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door NOTE: Explorer shown, Explorer Sport Trac similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1. Remove the side compartment lid. For additional information, refer to Pickup Bed Storage Compartment Lid - Side Compartment See: Truck Bed/Truck Bed Storage Compartment/Truck Bed Storage Compartment Door / Cover/Service and Repair/Pickup Bed Storage Compartment Lid - Side Compartment. 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 (V6-4.0L (2009)) 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 8101 Truck Bed Storage Compartment Weatherstrip: Service and Repair Pickup Bed Storage Compartment Seal - Front Compartment Pickup Bed Storage Compartment Seal - Front Compartment 1. Remove the front compartment lid. For additional information, refer to Pickup Bed Storage Compartment Lid - Front Compartment See: Truck Bed/Truck Bed Storage Compartment/Truck Bed Storage Compartment Door / Cover/Service and Repair/Pickup Bed Storage Compartment Lid - Front Compartment. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8106 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8107 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 8110 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation Engine Control Components 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. Typical Clutch Pedal Position (CPP) Switch Typical Clutch Pedal Position (CPP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair Speed Control Switch NOTE: Explorer shown, Mountaineer similar. Removal and Installation NOTE: It is not necessary to remove the driver air bag module during this procedure. NOTE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8121 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8122 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8125 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and Operation Clutch Switch: Description and Operation Engine Control Components 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. Typical Clutch Pedal Position (CPP) Switch Typical Clutch Pedal Position (CPP) Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: Explorer shown, Mountaineer similar. Removal and Installation NOTE: It is not necessary to remove the driver air bag module during this procedure. NOTE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Diagrams > Page 8136 Air Bag Deactivation Indicator: Service and Repair Passenger Air Bag Deactivation (PAD) Indicator Removal and Installation 1. NOTE: Ignition must be OFF if disconnecting the Passenger Air Bag Deactivation (PAD) indicator electrical connector. Otherwise, a DTC will be set in the Restraints Control Module (RCM) memory and must be cleared before releasing the vehicle. Turn the ignition OFF and wait at least one minute. 2. Remove the floor console. 3. Gently pull outward to release the clips on the instrument panel center finish panel. 4. Disconnect the PAD indicator electrical connector. 5. Remove the 2 screws and PAD indicator. 6. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8141 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8142 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8143 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8144 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8145 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8146 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8147 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8148 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8149 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8150 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8151 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8152 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8153 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8154 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8155 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8156 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8157 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8158 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8159 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 (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams can be found at Diagrams By Number. See: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8160 Diagrams/Electrical Diagrams/Diagrams By Number Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams can be found at Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment Compass: Service and Repair Compass Zone Adjustment Compass Zone Adjustment With Message Center 1. Turn the ignition switch to the ON position. 2. From the SETUP menu, select compass zone. 3. Determine which magnetic zone you are in for your geographic location. 4. Press the RESET button until the message center display changes to show the current zone setting. 5. Press the RESET button repeatedly until the correct zone setting for your geographic location is displayed. 6. Wait 4 seconds when the correct zone is chosen. Without Message Center - Early Build 1. Turn the ignition switch to the ON position. 2. Locate the reset button on top of the compass sensor located behind the mirror. 3. Determine which magnetic zone you are in for your geographic location. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment > Page 8166 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. Without Message Center - Late Build 1. Turn the ignition switch to the ON position. 2. Determine which magnetic zone you are in for your geographic location. 3. Press and release the SELECT/RESET button until HOLD RESET FOR SYSTEM CHECK is displayed in the integrated circuit display. 4. Quickly release the SELECT/RESET button. 5. Press and release the SELECT/RESET button to scroll through the setup menu until COMPASS ZONE XX is displayed in the integrated circuit display. 6. Press and hold the SELECT/RESET button for approximately 2 seconds to enter the compass zone setting mode. 7. Press and release the SELECT/RESET button until the correct zone setting for your geographic location appears in the integrated circuit display. 8. Release the SELECT/RESET button and allow the setup timer to expire to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment > Page 8167 Compass: Service and Repair Compass Calibration Compass Calibration With Message Center 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater, A/C, map lamps, wipers, heated windshield, 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 takes up to 5 circles to complete the calibration. NOTE: 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 - Early Build 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, heated windshield, 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 until CIRCLE SLOWLY TO CALIBRATE is displayed and release. 4. NOTE: It takes up to 5 circles to complete the calibration. NOTE: 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 (IC) display. Without Message Center - Late Build 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, heated windshield, etc.) and make sure all doors are closed. Start the vehicle. 2. Press and release the SELECT/RESET button to scroll through the information menu until HOLD RESET FOR SYSTEM CHECK is displayed. 3. Quickly release the SELECT/RESET button. 4. Press and release the SELECT/RESET button to scroll through the setup menu until COMPASS ZONE XX is displayed in the integrated circuit Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Zone Adjustment > Page 8168 display. 5. Press and hold the SELECT/RESET button for approximately 2 seconds to enter the compass zone setting mode. 6. Release the SELECT/RESET button. 7. Press and hold the SELECT/RESET button until CIRCLE SLOWLY TO CALIBRATE appears in the integrated display. 8. NOTE: It can take up to 5 circles to complete the calibration. 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 IC display. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. 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 this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagram. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition to OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8174 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8175 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the cover and RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8176 7. Remove the 2 driver air bag module bolts (1 shown). 8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Open and lower the glove compartment door. 10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield. 11. NOTE: The canister vent and adaptive tether do not require deactivation. Disconnect the LH side passenger air bag module electrical connector. 12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Disengage the passenger seat side air bag module electrical connector locking clip, release the tab and disconnect the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 13. Release and position aside the passenger side C-pillar trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8177 14. Disconnect the passenger side safety canopy module electrical connector. 15. Release and position aside the driver side C-pillar trim panel. 16. Disconnect the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 17. Remove the driver and passenger side upper C-pillar trim panels. 18. Disconnect the passenger side safety canopy module electrical connector. 19. Disconnect the driver side safety canopy module electrical connector. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8178 20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module electrical connector locking clip, release the tab and disconnect the driver seat side air bag module electrical connector. 21. Install the RCM fuse 17 (10A) to the SJB. 22. 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. 3. Connect the driver seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles 4. Connect the driver side safety canopy module electrical connector. 5. Connect the passenger side safety canopy module electrical connector. 6. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 7. Connect the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8179 8. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 11. Connect the passenger seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Attach the passenger seat side air bag module electrical connector to the seat track bracket. 12. Connect the LH side passenger air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8180 13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer. 14. NOTICE: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. 15. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 16. Turn the ignition switch from OFF to ON. 17. Install RCM fuse 17 (10A) to the SJB and install the cover. 18. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 19. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Service and Repair 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8188 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8189 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8190 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8191 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8194 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8195 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8196 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8197 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door Door Ajar Switch - Front Door Removal and Installation 1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8200 Door Switch: Service and Repair Door Ajar Switch - Liftgate Door Ajar Switch - Liftgate Removal and Installation 1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8201 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass Door Ajar Switch - Liftgate Glass Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8202 Door Switch: Service and Repair Door Ajar Switch - Rear Door Door Ajar Switch - Rear Door Removal and Installation 1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations > Page 8206 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure Driver/Vehicle Information Display: Reset Procedure Message Center Configuration Oil Life Reset And Start Value - With Message Center NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Without Message Center NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Reset Procedure > Page 8209 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8218 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8224 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 there is a concern in the EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly. This is detected by the inability to pull vacuum in the fuel tank after a fueling event. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Engine Control Components 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. Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 8233 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir Engine Control Components 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 ignition 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 8234 Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 8235 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 8236 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation > Page 8237 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Depowering Procedure WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. 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 this instruction may result in the accidental deployment of the Safety Canopy(R) and cause serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagram. 4. Turn the ignition ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition to OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Repowering Procedure 1. Turn the ignition switch from OFF to ON. 2. Install RCM fuse 17 (10A) to the SJB and close the cover. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8243 3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 4. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8244 Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS) Deactivation and Reactivation Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim cover/tear seam pointed away from the body. Do not set a live air bag module down with the deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain modules. Failure to follow this instruction may result in the accidental deployment of these modules, which increases the risk of serious personal injury or death. WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or adaptive load limiting retractors. Failure to follow this instruction may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the risk of serious personal injury or death. WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices. Failure to follow this instruction may result in serious personal injury or death. NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is removed and the ignition is ON. NOTE: The Supplemental Restraint System (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 OFF. 3. At the Smart Junction Box (SJB), located below the LH side of the instrument panel, remove the cover and RCM fuse 17 (10A) from the SJB. For additional information, refer to the Wiring Diagrams. 4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30 seconds. The air bag warning indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. 6. WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM). Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the Description and Operation of Air Bag Systems for location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment. Disconnect the battery ground cable and wait at least one minute. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8245 7. Remove the 2 driver air bag module bolts (1 shown). 8. Disconnect the 3 driver air bag module electrical connectors and remove the driver air bag module. 9. Open and lower the glove compartment door. 10. Detach the wiring retainer, remove the 4 bolts and passenger air bag module heat shield. 11. NOTE: The canister vent and adaptive tether do not require deactivation. Disconnect the LH side passenger air bag module electrical connector. 12. Under the rear of the passenger seat, detach the passenger seat side air bag module electrical connector from the seat track bracket. Disengage the passenger seat side air bag module electrical connector locking clip, release the tab and disconnect the passenger seat side air bag module electrical connector. Explorer and Mountaineer vehicles 13. Release and position aside the passenger side C-pillar trim panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8246 14. Disconnect the passenger side safety canopy module electrical connector. 15. Release and position aside the driver side C-pillar trim panel. 16. Disconnect the driver side safety canopy module electrical connector. Explorer Sport Trac vehicles 17. Remove the driver and passenger side upper C-pillar trim panels. 18. Disconnect the passenger side safety canopy module electrical connector. 19. Disconnect the driver side safety canopy module electrical connector. All vehicles Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8247 20. Under driver seat, the rear of the slide and disengage the driver seat side air bag module electrical connector locking clip, release the tab and disconnect the driver seat side air bag module electrical connector. 21. Install the RCM fuse 17 (10A) to the SJB. 22. 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. 3. Connect the driver seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Explorer Sport Trac vehicles 4. Connect the driver side safety canopy module electrical connector. 5. Connect the passenger side safety canopy module electrical connector. 6. Install the driver and passenger upper C-pillar trim panels. Explorer and Mountaineer vehicles 7. Connect the driver side safety canopy module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8248 8. Install the driver side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. 9. Connect the passenger side safety canopy module electrical connector. 10. Install the passenger side C-pillar trim panel. - Verify the safety belt retractor operates without excessive effort or binding. All vehicles 11. Connect the passenger seat side air bag module electrical connector and engage the seat side air bag electrical connector locking clip. Attach the passenger seat side air bag module electrical connector to the seat track bracket. 12. Connect the LH side passenger air bag module electrical connector. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8249 13. Install the passenger air bag module heat shield and 4 bolts. Attach the wiring retainer. 14. NOTICE: The driver air bag module electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module. Damage to the connector or component may occur. Connect the driver air bag module electrical connectors as noted in removal. 15. Install the 2 driver air bag module bolts (1 shown). - Tighten to 7 Nm (62 lb-in). 16. Turn the ignition switch from OFF to ON. 17. Install RCM fuse 17 (10A) to the SJB and install the cover. 18. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of any air bag module when the battery is connected. Failure to follow these instructions may result in serious personal injury in the event of an accidental deployment. Connect the battery ground cable. 19. 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 warning indicator with the air bag modules installed. The air bag warning indicator will light continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the air bag warning indicator will: - fail to light. - remain lit continuously. - flash at a 5 Hz rate (RCM not configured). The air bag warning 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 warning indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification System Module (OCSM) using a scan tool. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb 1. Remove the Instrument Cluster (IC). 2. NOTE: To remove the illumination bulb, rotate the bulb one quarter turn counterclockwise and lift out from the IC. Remove the illumination bulb(s). 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8261 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8267 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures Maintenance Required Lamp/Indicator: Procedures Message Center Configuration Oil Life Reset And Start Value - High Series Instrument Cluster NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset And Start Value - Base Instrument Cluster NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair > Procedures > Page 8272 Maintenance Required Lamp/Indicator: Reset Procedure Oil Life Reset and Start Value - With Message Center Message Center Configuration Oil Life Reset And Start Value - With Message Center NOTE: The oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. 1. From the setup menu, press and release the RESET button to display HOLD RESET IF NEW OIL. 2. Press and hold the RESET button for 2 seconds and release to reset the oil life to 100%. 3. The message center displays OIL LIFE SET TO 100%. 4. Once the message center displays OIL LIFE SET TO 100%, release the RESET button then press and release the RESET button to reduce the start value (10% for each button press). Oil Life Reset and Start Value - Without Message Center Message Center Configuration Oil Life Reset And Start Value - Without Message Center NOTE: Oil life calculation is set at a maximum of approximately 12,000 km (7,500 miles) or 180 days. NOTE: All message center functions are carried out using the single stem reset button in the Instrument Cluster (IC). 1. Press and release the SELECT/RESET button to scroll through the information displays until the message center displays HOLD RESET IF NEW OIL. 2. Press and hold the SELECT/RESET button for approximately 2 seconds until the message center displays OIL LIFE SET TO 100%. 3. Once OIL LIFE SET TO 100% is displayed, press and hold the SELECT/RESET button for more than 2 seconds until the message center displays OIL LIFE SET TO XXX%. 4. Press and release the SELECT/RESET button to reduce the start value (10% for each button press). 5. Press and release the SELECT/RESET button to exit the procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The 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 four 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 three 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/No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index. - 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 ignition in the RUN position (engine not running) if DTC P1000 is set. CHECK ENGINE, SERVICE ENGINE SOON, or ISO Standard Engine Symbol Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8284 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 (V6-4.0L (2009)) 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 8285 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8290 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8296 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 (V6-4.0L (2009)) 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 8297 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8302 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8306 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 8307 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams Parking Assist Warning Indicator: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Diagrams > Page 8311 Parking Assist Warning Indicator: Service and Repair Parking Aid Speaker Removal and Installation 1. Remove the LH C-pillar trim panel. 2. Remove the bolt and the speaker and bracket assembly. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8315 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8316 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8326 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8332 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8341 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 8347 Diagnosis Or Labor Performed As Actual Time) DEALER CODING CONDITION BASIC PART NO. CODE 10849 04 Disclaimer Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing any active occupant restraint components, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Warning System The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to Diagnosis and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation > Page 8351 Seat Belt Reminder Buzzer: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the scan tool. 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and the front passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the ON position (do not start the engine). 2. Wait until the safety belt warning indicator turns off (approximately 1 minute). 3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt 9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning indicator illuminates for 3 seconds. 4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second flash sequence after a brief pause. 5. After confirmation, the deactivation/activation procedure is complete. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 System WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must be inspected by an authorized dealer to verify correct function: - Retractors - Buckles - Belt tension sensor (BTS) (if equipped) - Front safety belt buckle support assemblies (slide bar) (if equipped) - Safety belt shoulder belt height adjusters (if equipped) - Child safety seat tether bracket assemblies - Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only) If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash. After any crash that results in deployment of the driver and/or front outboard passenger safety belt pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious personal injury or death in a crash. When replacing any active occupant restraint components, use only the replacement parts specified in the Ford Customer Service Division Master Parts and Accessories Catalog. Safety Belt Warning System The safety belt warning system is a reminder to fasten the driver safety belt. Refer to Diagnosis and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics. Belt-Minder(R) The Belt-Minder(R) feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled. Refer to Diagnosis and Testing, Safety Belt System See: Restraint Systems/Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 8355 Seat Belt Reminder Lamp: Service and Repair Belt-Minder(R) Deactivating/Activating Preparation NOTE: The Belt-Minder(R) Deactivating/Activating procedure can also be carried out using the scan tool. 1. Apply the parking brake before deactivating/activating the Belt-Minder(R). 2. Place the gear selector lever in PARK (P). 3. Place the ignition switch in the OFF position. 4. Close all the vehicle doors. 5. Unbuckle the driver and the front passenger safety belts. Deactivating/Activating 1. Turn the ignition switch to the ON position (do not start the engine). 2. Wait until the safety belt warning indicator turns off (approximately 1 minute). 3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns off. For the seating position being disabled, at a moderate speed, buckle then unbuckle the safety belt 9 times, ending with the safety belt in the unbuckled state. After this step the safety belt warning indicator illuminates for 3 seconds. 4. Within 5 seconds after the safety belt warning indicator turns off, at a moderate speed, buckle then unbuckle the safety belt. - This disables the Belt-Minder(R) feature for that seating position, if it is currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds. - This enables the Belt-Minder(R) feature for that seating position, if it is currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for 3 seconds followed by a second flash sequence after a brief pause. 5. After confirmation, the deactivation/activation procedure is complete. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Service and Repair 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. 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 (V6-4.0L (2009)) 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8364 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8365 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8366 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8367 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8370 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8371 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8372 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8373 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door Door Ajar Switch - Front Door Removal and Installation 1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8376 Door Switch: Service and Repair Door Ajar Switch - Liftgate Door Ajar Switch - Liftgate Removal and Installation 1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8377 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass Door Ajar Switch - Liftgate Glass Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8378 Door Switch: Service and Repair Door Ajar Switch - Rear Door Door Ajar Switch - Rear Door Removal and Installation 1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams Fuel Gauge Sender: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module Engine Control Components 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. Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Electronic Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Typical Mechanical Returnless Fuel Pump (FP) Module Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 8384 Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir Engine Control Components 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 ignition 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 8385 Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View Explorer Sport Trac NOTE: Vehicle body removed from art for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 8386 Explorer/Mountaineer NOTE: Vehicle body removed for clarity. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 8387 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation > Page 8388 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8392 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8393 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Training Tire Pressure Monitoring System (TPMS) Sensor Training 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). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Testing and Inspection/Programming and Relearning. 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. 6. 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. 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 8399 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. 8. 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. 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. 10. 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. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 8400 Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor Activation Tire Pressure Monitoring System (TPMS) Sensor Activation NOTE: The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information. 1. Turn the ignition switch to the ON position. 2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem. 3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response from a tire pressure sensor. Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times. 4. Repeat Steps 2 and 3 for the remaining tires. 5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart in Diagnosis and Testing. See: Testing and Inspection/Symptom Related Diagnostic Procedures Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed. Remove the tire from the wheel. For additional information, refer to Wheel and Tire See: Maintenance/Wheels and Tires/Service and Repair/Overhaul. 2. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur. Using a pocket screwdriver or similar tool, remove the sensor locking clip. 3. NOTICE: Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur. Using a pocket screwdriver or similar tool, detach the sensor from the cradle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8403 4. Remove the sensor. Assembly 1. NOTICE: Damage to the sensor may 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. 3. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire See: Maintenance/Wheels and Tires/Service and Repair/Overhaul. 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 See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8404 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring System (TPMS) Strap and Cradle Tire Pressure Monitoring System (TPMS) Strap and Cradle Disassembly WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material disposal. Failure to follow these instructions may result in serious personal injury. NOTE: Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly. NOTE: 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. 1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor See: Tire Pressure Monitoring System (TPMS) Sensor. 2. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8405 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. Remove a factory-installed strap in the following 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 in) from the buckle. 2. Using a large screwdriver and a twisting motion, unbuckle the strap. 3. Discard the strap. 3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear. - Discard the strap. 4. 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. NOTICE: Metal scrapers may 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. Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed. 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 degrees from the valve stem. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8406 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. NOTICE: Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid damaging the sensor during wheel and tire disassembly and assembly. 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 in) away from the sensor and tighten the worm gear. - Tighten to 3 Nm (27 lb-in). 6. NOTICE: The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed. Install the tire onto the wheel. For additional information, refer to Wheel and Tire. See: Maintenance/Wheels and Tires/Service and Repair/Overhaul 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. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Engine Control Components 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8414 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8415 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 8420 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 8421 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 Brake Lamp: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8447 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8448 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8449 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8450 90-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Special Tools Used With Diagnostics Stoplamps Principles Of Operation Stoplamps Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The SJB monitors the input from the stoplamp switch. When the brake pedal is applied, voltage is routed to the SJB. The SJB then supplies voltage to the stoplamps. Field-Effect Transistor (FET) Protection The SJB utilizes a Field-Effect Transistor (FET) protective circuit strategy for many of its outputs (for example, a headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault event is detected. A continuous DTC is stored at the fault event and a cumulative counter is started. When the demand for the output is no longer present, the module resets the FET circuit protection to allow the circuit to function. The next time the driver requests a circuit to activate that has been shut down by a previous short (FET protection) and the circuit remains shorted, the FET protection shuts off the circuit again and the cumulative counter advances. When the excessive circuit load occurs often enough, the module shuts down the output until a repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to withstand it. A module lifetime level of fault events is established based upon the durability of the FET. If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would be 200, 400 and 600 fault events. When each tolerance level is reached, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal operation until a successful self-test proves that the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs present), the continuous DTC automatically clears and the circuit function returns. When the first or second level is reached, the continuous DTC (associated with the short circuit) sets along with DTC B106E. These DTCs can be cleared using the module on-demand self-test, then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected). The module never resets the fault event counter to zero and continues to advance the fault event counter as short circuit fault events occur. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8453 If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set along with the associated continuous DTC. This DTC cannot be cleared and the module must be replaced. Inspection And Verification Stoplamps Inspection and Verification 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart 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. NOTE: Make sure the multifunction switch is in the LOW BEAM position. 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, No Power To The Scan Tool, to diagnose no power to 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 to diagnose no response from the PCM. 7. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus. - 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 Diagnostic Trouble Code (DTC) Chart See: Testing and Inspection. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8454 Brake Lamp: Symptom Related Diagnostic Procedures Stoplamps Symptom Chart Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8455 Brake Lamp: Pinpoint Tests Pinpoint Test I: One Or More Stoplamps Are Inoperative Stoplamps Pinpoint Tests Pinpoint Test I: One Or More Stoplamps Are Inoperative Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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). Explorer When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG). 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). Explorer Sport Trac When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG). 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). Mountaineer When the SJB detects the brake pedal is 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). B2048-B2051 / C1788 This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - High mounted stoplamp - LED module - SJB PINPOINT TEST I: ONE OR MORE STOPLAMPS ARE INOPERATIVE Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8456 NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- I1 CHECK THE RECORDED DTCs FROM THE SJB SELF-TEST - Check the recorded results from the SJB self-test. - Is DTC C1788, B2048 or B2050 recorded? Yes For DTC C1788, GO to I2. For DTC B2048 or B2050, GO to I5. No GO to I7. ------------------------------------------------- I2 CHECK THE LH LED MODULE FOR A SHORT TO GROUND - Disconnect: LH Rear Lamp C419. - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the DTCs and repeat the SJB on-demand self-test. - Is DTC C1788 still present? Yes GO to I3. No INSTALL a new LED module. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. ------------------------------------------------- I3 CHECK THE RH LED MODULE FOR A SHORT TO GROUND - Disconnect: RH Rear Lamp C418. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the DTCs and repeat the SJB on-demand self-test. - Is DTC C1788 still present? Yes GO to I4. No INSTALL a new LED module. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. ------------------------------------------------- I4 CHECK CIRCUIT CLS44 (VT/BN) FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280a. - Measure the resistance between the LH rear lamp C419-1, circuit CLS44 (VT/BN), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8457 - Is the resistance greater than 10,000 ohms? Yes GO to I15. No VERIFY the SJB fuse 27 (15A) is OK. If OK, REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- I5 CHECK THE BULB HOLDER FOR A SHORT TO GROUND - Disconnect: Inoperative Stoplamp. - Ignition ON. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the DTCs and repeat the SJB on-demand self-test. - Is DTC B2048 or B2050 still present? Yes GO to I6. No INSTALL a new bulb holder in question. TEST the system for normal operation. ------------------------------------------------- I6 CHECK CIRCUIT CLS18 (GY/BN) OR CLS19 (VT/OG) FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280a. - For Explorer, measure the resistance between the inoperative rear lamp, harness side and ground as follows: - For Explorer Sport Trac, measure the resistance between the inoperative rear lamp, harness side and ground as follows: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8458 - Is the resistance greater than 10,000 ohms? Yes GO to I15. No VERIFY the SJB fuse 22 (15A) is OK. If OK, REPAIR the circuit in question. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- I7 DETERMINE THE INOPERATIVE STOPLAMP - Ignition OFF. - Apply the brake pedal. - Verify the high mounted stoplamp operation. - Is the high mounted stoplamp illuminated? Yes If one rear stoplamp is inoperative, GO to I11. For Mountaineer, if both rear stoplamps are inoperative, GO to I13. For Explorer Sport Trac, if both rear stoplamps are inoperative, GO to I14. For Explorer, if both rear stoplamps are inoperative, GO to I15. No GO to I8. ------------------------------------------------- I8 CHECK CIRCUIT CCB08 (VT/WH) FOR VOLTAGE - For Explorer or Mountaineer, while applying the brake pedal, measure the voltage between the high mounted stoplamp C475-1, circuit CCB08 (VT/WH), harness side and ground. - For Explorer Sport Trac, while applying the brake pedal, measure the voltage between the high mounted stoplamp C927-3, circuit CCB08 (VT/WH), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8459 - Is the voltage greater than 10 volts? Yes GO to I9. No GO to I10. ------------------------------------------------- I9 CHECK THE HIGH MOUNTED STOPLAMP GROUND CIRCUIT FOR AN OPEN - Disconnect: Negative Battery Cable. - Disconnect: High Mounted Stoplamp C475 (Explorer, Mountaineer) or C927 (Explorer Sport Trac). - For Explorer or Mountaineer, measure the resistance between the high mounted stoplamp C475-2, circuit GD149 (BK/GY), harness side and ground. - For Explorer Sport Trac, measure the resistance between the high mounted stoplamp C927-1, circuit GD133 (BK), harness side and ground. - Is the resistance less than 5 ohms? Yes INSTALL a new high mounted stoplamp. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- I10 CHECK CIRCUIT CCB08 (VT/WH) FOR AN OPEN - Disconnect: SJB C2280a. - For Explorer or Mountaineer, measure the resistance between the high mounted stoplamp C475-1, circuit CCB08 (VT/WH), harness side and the SJB C2280a-15, circuit CCB08 (VT/WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8460 - For Explorer Sport Trac, measure the resistance between the high mounted stoplamp C927-3, circuit CCB08 (VT/WH), harness side and the SJB C2280a-15, circuit CCB08 (VT/WH), harness side. - Is the resistance less than 5 ohms? Yes GO to I15. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- I11 CHECK THE REAR LAMP GROUND CIRCUIT FOR AN OPEN - Place the headlamp switch in the PARKING LAMPS ON position. - Does the rear lamp in question illuminate? Yes For Mountaineer, TURN the parking lamps off. GO to I12. For Explorer or Explorer Sport Trac, TURN the parking lamps off. GO to I13. No REPAIR the ground circuit in question for an open. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- I12 CHECK CIRCUIT CLS44 (BU/RD) FOR AN OPEN - Disconnect: Inoperative Rear Lamp. - While applying the brake pedal, measure the voltage between the LH rear lamp (LED module) C419-1, circuit CLS44 (BU/RD), harness side and ground; or between the RH rear lamp (LED module) C418-1, circuit CLS44 (BU/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8461 INSTALL a new LED module. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- I13 CHECK THE REAR STOPLAMP VOLTAGE SUPPLY CIRCUIT FOR AN OPEN - Disconnect: Inoperative Rear Lamp. - Disconnect: SJB C2280a. - Measure the resistance between the inoperative rear lamp, harness side and the SJB, harness side as follows: - Is the resistance less than 5 ohms? Yes GO to I15. No REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- I14 CHECK CIRCUIT GD148 (BK/YE) FOR AN OPEN - Place the headlamp switch in the PARKING LAMPS ON position. - Are both rear parking lamps inoperative? Yes REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. No GO to I15. ------------------------------------------------- I15 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8462 Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------Pinpoint Test H: All The Stoplamps Are Inoperative Stoplamps Pinpoint Tests Pinpoint Test H: All The Stoplamps Are Inoperative Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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) which then supplies voltage to all the stoplamps. This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Stoplamp switch - SJB PINPOINT TEST H: ALL THE STOPLAMPS ARE INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- H1 CHECK CIRCUIT SBP22 (BN/RD) FOR VOLTAGE - Ignition OFF. - Disconnect: Stoplamp Switch C278. - Measure the voltage between the stoplamp switch C278-1, circuit SBP22 (BN/RD), harness side and ground. - Is the voltage greater than 10 volts? Yes GO to H3. No VERIFY the SJB fuse 22 (15A) is OK. If OK, GO to H2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- H2 CHECK CIRCUIT SBP22 (BN/RD) FOR AN OPEN Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8463 - Disconnect: SJB C2280e. - Measure the resistance between the stoplamp switch C278-1, circuit SBP22 (BN/RD), harness side and the SJB C2280e-28, circuit SBP22 (BN/RD), harness side. - Is the resistance less than 5 ohms? Yes GO to H5. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- H3 CHECK THE STOPLAMP SWITCH - Connect a fused jumper wire between the stoplamp switch C278-1, circuit SBP22 (BN/RD), harness side and the stoplamp switch C278-4, circuit CCB08 (VT/WH), harness side. - Do the stoplamps illuminate? Yes REMOVE the jumper wire. INSTALL a new stoplamp switch. REFER to Stoplamp Switch See: Brake Light Switch/Service and Repair. TEST the system for normal operation. No REMOVE the jumper wire. GO to H4. ------------------------------------------------- H4 CHECK CIRCUIT CCB08 (VT/WH) FOR AN OPEN - Disconnect: SJB C2280e. - Measure the resistance between the stoplamp switch C278-4, circuit CCB08 (VT/WH), harness side and the SJB C2280e-23, circuit CCB08 (VT/WH), harness side. Is the resistance less than 5 ohms? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8464 GO to H5. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- H5 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test J: The Stoplamps Are On Continuously Stoplamps Pinpoint Tests Pinpoint Test J: The Stoplamps Are On Continuously Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Refer to Wiring Diagram Set 42, Vehicle Dynamic Systems for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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 Brake Control (TBC) module, the ABS module, and the 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). Explorer, Explorer Sport Trac When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuits CLS18 (GY/BN) and CLS19 (VT/OG). Mountaineer When the SJB detects the brake pedal is applied, the SJB provides voltage to the LH and RH rear stoplamps through circuit CLS44 (VT/BN). - DTC B1446 (Brake Switch Circuit Failure) - an on-demand DTC that sets when the SJB detects a short to voltage from the brake pedal applied input circuit. - DTC B2049 (Left Rear Turn Lamp Circuit Open) - a continuous and on-demand DTC that sets when the SJB detects a short to voltage from the LH rear turn lamp voltage supply circuit. - DTC B2051 (Right Rear Turn Lamp Circuit Open) - a continuous and on-demand DTC that sets when the SJB detects an open from the RH rear turn lamp voltage supply circuit. This pinpoint test is intended to diagnose the following: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8465 - Wiring, terminals or connectors - Stoplamp switch - TBC module - Brake shift interlock actuator - ABS module - PCM - SJB PINPOINT TEST J: THE STOPLAMPS ARE ON CONTINUOUSLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. ------------------------------------------------- J1 DETERMINE IF ALL THE STOPLAMPS ARE ILLUMINATED - Ignition OFF. - Observe the stoplamps with the brake pedal released. - Are all of the stoplamps illuminated? Yes GO to J2. No GO to J9. ------------------------------------------------- J2 CHECK THE STOPLAMP SWITCH - Disconnect: Stoplamp Switch C278. - Do the stoplamps continue to illuminate? Yes GO to J3. No INSTALL a new stoplamp switch. REFER to Stoplamp Switch See: Brake Light Switch/Service and Repair. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J3 CHECK THE BRAKE SHIFT INTERLOCK ACTUATOR - Disconnect: Brake Shift Interlock Actuator C2008. - Do the stoplamps continue to illuminate? Yes GO to J4. No INSTALL a new brake shift interlock actuator. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J4 CHECK THE ABS MODULE - Disconnect: ABS Module C155. - Do the stoplamps continue to illuminate? Yes If equipped with a Trailer Brake Control (TBC) module, GO to J5. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8466 If not equipped with a TBC module, GO to J6. No GO to J10. ------------------------------------------------- J5 CHECK THE TBC MODULE - Disconnect: TBC Module C238. - Do the stoplamps continue to illuminate? Yes GO to J6. No INSTALL a new TBC module. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J6 CHECK THE PCM - Disconnect: PCM C175b. - Do the stoplamps continue to illuminate? Yes GO to J7. No GO to J12. ------------------------------------------------- J7 CHECK CIRCUIT CCB08 (VT/WH) FOR A SHORT TO VOLTAGE (TO OTHER MODULES) - Disconnect: SJB C2280c. - Do the stoplamps continue to illuminate? Yes GO to J8. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J8 CHECK CIRCUIT CCB08 (VT/WH) FOR A SHORT TO VOLTAGE (FROM STOPLAMP SWITCH) - Disconnect: SJB C2280e. - Do the stoplamps continue to illuminate? Yes GO to J9. No REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J9 CHECK CIRCUIT CCB08 (VT/WH) FOR A SHORT TO VOLTAGE (TO HIGH MOUNTED STOPLAMP) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8467 - Disconnect: SJB C2280a. - Do the stoplamps continue to illuminate? Yes If the high mounted stoplamp continues to illuminate, REPAIR circuit CCB08 (VT/WH). CLEAR the DTCs. REPEAT the self-test. For Explorer or Explorer Sport Trac, if the LH rear lamp continues to illuminate, REPAIR circuit CLS18 (GY/BN). CLEAR the DTCs. REPEAT the self-test. If the RH rear lamp continues to illuminate, REPAIR circuit CLS19 (VT/OG). CLEAR the DTCs. REPEAT the self-test. For Mountaineer, if the rear lamps continue to illuminate, REPAIR circuit CLS44 (VT/BN). CLEAR the DTCs. REPEAT the self-test. No GO to J11. ------------------------------------------------- J10 CHECK FOR CORRECT ABS MODULE OPERATION - Disconnect the ABS module connector. - Check for: corrosion - damaged pins - pushed-out pins - Connect the ABS module connector and make sure it seats correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new ABS module. CLEAR the DTCs. REPEAT the self-test. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J11 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- J12 CHECK FOR CORRECT PCM OPERATION - Disconnect all the PCM connectors. - Check for: corrosion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8468 - damaged pins - pushed-out pins - Connect all the PCM connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new PCM. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8472 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8473 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8474 Brake Light Switch: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8475 Brake Light Switch: Service and Repair Stoplamp Switch Removal and Installation NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Cargo Lamp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Cargo Lamp > Page 8480 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8492 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8493 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8494 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8495 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8496 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8497 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8498 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8499 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8500 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8501 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8502 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8503 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8504 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8505 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8506 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8507 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8508 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8509 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8510 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8511 97-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Daytime Running Lamp: Initial Inspection and Diagnostic Overview Principles Of Operation Daytime Running Lamps (DRL) Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The Daytime Running Lamps (DRL) feature operates the low beam headlamps at a reduced intensity when the ignition switch is in the RUN position, the headlamps are not on from any other input, and the transmission is not in PARK (P). 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 The DRL is not a programmable parameter for this vehicle. Special Tools Used With Diagnostics Daytime Running Lamps (DRL) Inspection And Verification Daytime Running Lamps (DRL) Inspection and Verification 1. Verify the customer concern. 2. 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. NOTE: Make sure the multifunction switch is not in the HIGH BEAM position. 3. 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). 4. 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, No Power To The Scan Tool, to diagnose no power to the scan tool. 5. If the scan tool does not communicate with the vehicle: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8514 - Verify the ignition key is in the ON position. - Verify the scan tool operation with a known good vehicle. - Refer to Information Bus to diagnose no response from the PCM. 6. Carry out the network test. - If the scan tool responds with no communication for one or more modules, refer to Information Bus. - If the network test passes, retrieve and record the continuous memory DTCs. 7. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8515 Daytime Running Lamp: Symptom Related Diagnostic Procedures Daytime Running Lamps (DRL) Symptom Chart Symptom Chart Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8516 Daytime Running Lamp: Pinpoint Tests Daytime Running Lamps (DRL) Pinpoint Tests Pinpoint Test AE: The Daytime Running Lamps (DRL) Are Inoperative Normal Operation When the ignition switch is in the RUN position, the headlamps are not on (from the autolamp system or manual control from the headlamp switch) and the transmission is not in PARK (P), the Smart Junction Box (SJB) provides a pulse-width modulated voltage to the low beam headlamps. This illuminates the headlamps at a reduced intensity. This pinpoint test is intended to diagnose the following: - Exterior lighting system input/output - Ignition switch input - Transmission gear input - SJB PINPOINT TEST AE: THE DRL ARE INOPERATIVE ------------------------------------------------- AE1 VERIFY THE DRL OPERATION - Ignition ON. - Place the headlamp switch in the OFF position. - Place the gear selector lever in any gear other than PARK (P). - Are the DRL illuminated? Yes The system is operating correctly. INFORM the customer of the conditions required for the DRL to operate correctly. No GO to AE2. ------------------------------------------------- AE2 CHECK THE OPERATION OF THE HEADLAMPS - Place the headlamp switch in the HEADLAMPS ON position and observe the headlamps. - Do the headlamps operate correctly? Yes GO to AE3. No REFER to Headlamps See: Headlamp/Testing and Inspection. ------------------------------------------------- AE3 CHECK THE IGNITION SWITCH INPUT - Place the headlamp switch in the OFF position. - Enter the following diagnostic mode on the scan tool: SJB DataLogger. - Monitor the SJB ignition switch PIDs (IGN_A_ECU, IGN_O_ECU, IGN_R_ECU, IGN_S_ECU) while cycling the ignition switch through all its positions. - Do the PIDs agree with the ignition switch positions? Yes GO to AE4. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8517 No REFER to Steering Column to diagnose the input from the ignition switch. See: Steering and Suspension/Steering/Steering Column/Testing and Inspection ------------------------------------------------- AE4 CHECK THE TRANSMISSION GEAR INPUT - Enter the following diagnostic mode on the scan tool: PCM or TCM DataLogger. - Monitor the PCM or TCM transmission gear status PID (TR) while placing the gear selector lever through all its positions. - Does the PID agree with the gear selection? Yes INSTALL a new SJB. TEST the system for normal operation. No REFER to Transmission Control Systems to diagnose the transmission range input. See: Powertrain Management/Transmission Control Systems/Testing and Inspection ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Testing and Inspection > Page 8518 Daytime Running Lamp: Adjustments Autolamps Time Delay Adjustment NOTE: Steps 2 through 5 must be carried out within a 10-second period. 1. Start with the ignition switch OFF position and the headlamp switch in the AUTOLAMPS ON position. 2. Place the headlamp switch in the OFF position. 3. Place the ignition switch in the RUN position. 4. Place the ignition switch in the OFF position. 5. Place the headlamp switch in the AUTOLAMPS ON position. The exterior lamps turn on at this point. 6. Wait the desired amount of time and place the headlamp switch in the OFF position (maximum of 3 minutes). The exterior lamps turn off and the autolamp time delay is now set. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair 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. 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Interior Lamp - Front > Page 8526 Dome Lamp: Service and Repair Interior Lamp - Rear Interior Lamp - Rear Removal and Installation 1. Remove the rear interior lamp lens. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8531 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8532 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8533 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8534 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8537 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8538 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8539 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8540 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door Door Ajar Switch - Front Door Removal and Installation 1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8543 Door Switch: Service and Repair Door Ajar Switch - Liftgate Door Ajar Switch - Liftgate Removal and Installation 1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8544 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass Door Ajar Switch - Liftgate Glass Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8545 Door Switch: Service and Repair Door Ajar Switch - Rear Door Door Ajar Switch - Rear Door Removal and Installation 1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) 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 Base Fog Lamp Bulb NOTE: Explorer, Explorer Sport Trac shown, Mountaineer similar. Adrenalin Package Fog Lamp Bulb Removal and Installation WARNING: The 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Page 8550 NOTE: Make sure the headlamp switch and ignition switch are in the OFF position. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Vehicles with base fog lamp 2. NOTE: To remove, rotate the bulb approximately one-eighth turn counter clockwise. Disconnect the electrical connector and remove the fog lamp bulb. Vehicles with Adrenalin fog lamp 3. NOTE: To remove, squeeze the tabs and pull the fog lamp bulb from the fog lamp assembly. Disconnect the electrical connector and remove the fog lamp bulb. All vehicles 4. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8554 Fog/Driving Lamp Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8555 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 Hazard Warning 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8578 Hazard Warning 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. 90-1 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8579 90-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Mountaineer Removal and Installation WARNING: The 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. For additional information, refer to Headlamp Assembly See: Service and Repair. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 8588 Headlamp Dimmer Switch: Locations Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 8589 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 8592 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8595 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8596 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8597 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 8598 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8602 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8603 Headlamp Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8604 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8605 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8614 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8615 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8616 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8617 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8618 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8619 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8620 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 License Plate Lamp: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8648 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8649 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8650 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8651 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8652 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8653 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8654 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8655 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8656 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8657 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 Marker Lamp: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8665 Marker Lamp: Service and Repair Side Marker Lamp NOTE: LH front shown, others similar. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair Parking Lamp Bulb - Front Explorer, Explorer Sport Trac Mountaineer Removal and Installation 1. Remove the headlamp assembly. For additional information, refer to Headlamp Assembly See: Headlamp/Service and Repair. 2. Remove the parking lamp bulb socket from the headlamp assembly. - Remove the parking lamp bulb from the socket. 3. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8677 Fog/Driving Lamp Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8678 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8685 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8686 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8691 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 8692 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8696 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8697 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8701 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8702 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8703 Brake Light Switch: Description and Operation Engine Control Components Brake Pedal Position (BPP) Switch The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal to the PCM indicating 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. Typical BPP Switch Typical BPP Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8704 Brake Light Switch: Service and Repair Stoplamp Switch Removal and Installation NOTICE: 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8709 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8710 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8711 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Driver Side Front > Page 8712 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8715 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8716 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8717 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Liftgate Glass Ajar Switch > Page 8718 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door Door Switch: Service and Repair Door Ajar Switch - Front Door Door Ajar Switch - Front Door Removal and Installation 1. Remove the front door latch. For additional information, refer to Front Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8721 Door Switch: Service and Repair Door Ajar Switch - Liftgate Door Ajar Switch - Liftgate Removal and Installation 1. Remove the liftgate latch. For additional information, refer to Liftgate Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8722 Door Switch: Service and Repair Door Ajar Switch - Liftgate Glass Door Ajar Switch - Liftgate Glass Removal and Installation 1. Remove the liftgate window latch. For additional information, refer to Liftgate Window Latch See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Ajar Switch - Front Door > Page 8723 Door Switch: Service and Repair Door Ajar Switch - Rear Door Door Ajar Switch - Rear Door Removal and Installation 1. Remove the rear door latch. For additional information, refer to Rear Door Latch See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Removal and Replacement/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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 8728 Headlamp Dimmer Switch: Locations Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Illumination Dimmer Switch > Page 8729 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Multifunction Switch > Page 8732 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch Headlamp Dimmer Switch: Testing and Inspection Illumination Dimmer Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8735 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8736 Headlamp Dimmer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Illumination Dimmer Switch > Page 8737 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 8738 Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8742 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8743 Headlamp Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8744 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8745 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8752 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8753 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8754 Turn Signal Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8755 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8756 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8761 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8762 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8763 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8764 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8765 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8766 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8767 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8768 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8769 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8770 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8771 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8772 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8773 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8774 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8775 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8776 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8777 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8778 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8779 Tail Lamp: Connector Views Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8780 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8781 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8782 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8783 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8784 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8785 92-2 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 the Power and Ground Distribution Diagrams. Full representation of the ground connections are shown in the Power and Ground Distribution Diagrams. Switch Positions (2) Within 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 diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be seen completely in the 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 parentheses next to or under a component. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8790 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 set 4 "Symbols". Fuse and Relay Information Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8791 Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which all 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 orientation. Power Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8792 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. Ground Distribution Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8793 Power and Ground Distribution Diagrams contains the diagram 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 diagrams as uncluttered as possible. 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 below the connector number. The circuit function charts are located below each connector. The wiring harness designations are listed in Component Location Charts. Component Location Views show the components and their connecting wires as they can be found on the vehicle. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8794 Locations 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 manual transmission should be in NEUTRAL. - Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide. - Keep away from moving parts, especially the fan and belts, when the engine is running. - To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. - Do not allow flame or sparks near the battery. Gases are always present in and around the battery set. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8795 Symbols (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8796 Symbols (Part 3) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8797 Symbols (Part 4) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8798 Symbols (Part 5) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8799 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 terminal by pulling each wire at the end of the connector. Defective insulation stripping 1 = Proper crimp Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8800 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation Partially mated connectors 1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8801 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 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8802 3 = Splice tape 4 = Harness tape Broken wire strands in harness 1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation Remove the tape and flex/feel each circuit for a reduction in diameter at break. Recommended splicing method - 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8803 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 seat 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8804 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 6.35mm (1/4 in) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8805 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, barrel squeeze tool handles appropriate 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8806 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8807 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8808 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8809 95-2 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8810 95-3 Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, 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 Location Views. See: Locations/Component Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 Special Tools Used With Diagnostics Trailer Lamps Principles Of Operation Trailer Lamps Principles of Operation NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). The SJB uses existing inputs to determine if voltage needs to be supplied to the individual trailer stop/turn lamps. The SJB has separate drivers that provide voltage for the trailer stop/turn lamps. The trailer parking and reversing lamps share the vehicle lighting outputs. The vehicle is supplied with wiring to support an aftermarket . The trailer tow battery charging is controlled by a relay. When the ignition switch is in the RUN or ACC position, the trailer tow battery charge relay is energized, which routes voltage to the trailer tow connector. Field-Effect Transistor (FET) Protection The SJB utilizes a Field-Effect Transistor (FET) protective circuit strategy for many of its outputs (for example, a headlamp output circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut down (turns off the voltage or ground provided by the module) when a fault event is detected. A continuous DTC is stored at the fault event and a cumulative counter is started. When the demand for the output is no longer present, the module resets the FET circuit protection to allow the circuit to function. The next time the driver requests a circuit to activate that has been shut down by a previous short (FET protection) and the circuit remains shorted, the FET protection shuts off the circuit again and the cumulative counter advances. When the excessive circuit load occurs often enough, the module shuts down the output until a repair procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit tolerance based on the harmful effect of each circuit fault on the FET and the ability of the FET to withstand it. A module lifetime level of fault events is established based upon the durability of the FET. If the total tolerance level is determined to be 600 fault events, the 3 predefined levels would be 200, 400 and 600 fault events. When each tolerance level is reached, the continuous DTC that was stored on the first failure cannot be cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the circuit restored to normal operation until a successful self-test proves that the fault has been repaired. After the self-test has successfully completed (no on-demand DTCs present), the continuous DTC automatically clears and the circuit function returns. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8813 When the first or second level is reached, the continuous DTC (associated with the short circuit) sets along with DTC B106E. These DTCs can be cleared using the module on-demand self-test, then the Clear DTC operation on the scan tool (if the on-demand test shows the fault corrected). The module never resets the fault event counter to zero and continues to advance the fault event counter as short circuit fault events occur. If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set along with the associated continuous DTC. This DTC cannot be cleared and the module must be replaced. The SJB FET protected output circuits for the trailer lamp system are the LH and RH trailer stop/turn output circuits. Inspection And Verification Trailer Lamps 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 for obvious signs of electrical damage. Visual Inspection Chart 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. NOTE: Make sure the multifunction switch is in the LOW BEAM position. 5. 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). 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, No Power To The Scan Tool, to diagnose no power to 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 to diagnose no response from the PCM. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8814 8. Carry out the network test. - If the scan tool responds with no communication with the SJB, refer to Information Bus. - 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 Diagnostic Trouble Code (DTC) Chart See: Testing and Inspection. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See: Body and Frame/Body Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) Chart 11. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8815 Trailer Lamps: Symptom Related Diagnostic Procedures Trailer Lamps Symptom Chart Symptom Chart (Part 1) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8816 Symptom Chart (Part 2) Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8817 Trailer Lamps: Pinpoint Tests Pinpoint Test W: All The Trailer Lamps Are Inoperative Trailer Lamps Pinpoint Tests Pinpoint Test W: All the Trailer Lamps Are Inoperative Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Ground for all the trailer lamps is provided through circuit RAT08 (WH). This pinpoint test is intended to diagnose the following: - Wiring, terminals or connectors - Trailer tow connector - Trailer PINPOINT TEST W: ALL THE TRAILER LAMPS ARE INOPERATIVE NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- W1 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN TO THE TRAILER TOW CONNECTOR - Disconnect the trailer from the vehicle. - Disconnect: Negative Battery Cable. - For the 4-pin connector, measure the resistance between the trailer tow C439-4, circuit RAT08 (WH), harness side and ground. - For the 7-pin connector, measure the resistance between the trailer tow connector pin 2, circuit RAT08 (WH), component side and ground. - Is the resistance less than 5 ohms? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8818 For the 4-pin connector, REPAIR the circuit. TEST the system for normal operation. For the 7-pin connector, GO to W2. ------------------------------------------------- W2 CHECK CIRCUIT RAT08 (WH) FOR AN OPEN - Disconnect: Trailer Tow C473. - Measure the resistance between the trailer tow C473-2, circuit RAT08 (WH), harness side and ground. - Is the resistance less than 5 ohms? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps Trailer Lamps Pinpoint Tests Pinpoint Test X: The Trailer Lamps Are Inoperative - Parking Lamps Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation When the vehicle parking lamps are on, the Smart Junction Box (SJB) provides voltage to the trailer parking lamps through circuit CAT17 (BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB PINPOINT TEST X: THE TRAILER LAMPS ARE INOPERATIVE - PARKING LAMPS NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- X1 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - Place the headlamp switch in the PARKING LAMPS ON position. - For the 4-pin connector, measure the voltage between the trailer tow C439-3, circuit CAT17 (BN), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8819 - For the 7-pin connector, measure the voltage between the trailer tow connector pin 6, circuit CAT17 (BN), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No VERIFY the SJB fuse 25 (15A) is OK. If OK for the 4-pin connector, GO to X3. If OK for the 7-pin connector, GO to X2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- X2 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C473. - Measure the voltage between the trailer tow C473-6, circuit CAT17 (BN), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to X3. ------------------------------------------------- X3 CHECK CIRCUIT CAT17 (BN) FOR AN OPEN - Place the headlamp switch in the OFF position. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-13, circuit CAT17 (BN), harness side and the trailer tow C439-3 (4-pin connector) or C473-6 (7-pin connector), circuit CAT17 (BN), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8820 - Is the resistance less than 5 ohms? Yes GO to X4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- X4 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps Trailer Lamps Pinpoint Tests Pinpoint Test Y: The Trailer Lamps Are Inoperative - Reversing Lamps Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Voltage to the trailer reversing lamps is supplied by the Smart Junction Box (SJB) through circuit CAT16 (GY/BN). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE - REVERSING LAMPS NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8821 connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- Y1 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - Apply the parking brake. - Ignition ON. - Select REVERSE. - Measure the voltage between the trailer tow connector pin 7, circuit CAT16 (GY/BN), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. No VERIFY the SJB fuse 16 (10A) is OK. If OK, GO to Y2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- Y2 CHECK FOR VOLTAGE ON CIRCUIT CAT16 (GY/BN) - Disconnect: Trailer Tow C473. - Measure the voltage between the trailer tow C473-7, circuit CAT16 (GY/BN), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to Y3. ------------------------------------------------- Y3 CHECK CIRCUIT CAT16 (GY/BN) FOR AN OPEN - Select PARK. - Ignition OFF. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-21, circuit CAT16 (GY/BN), harness side and the trailer tow C473-7, circuit CAT16 (GY/BN), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8822 - Is the resistance less than 5 ohms? Yes GO to Y4. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- Y4 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp Trailer Lamps Pinpoint Tests Pinpoint Test Z: The Individual Trailer Lamp Is Inoperative - LH Stop/Turn Lamp Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Voltage to the LH trailer stop/turn lamp is supplied by the Smart Junction Box (SJB) through circuit CAT06 (YE). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - a continuous DTC that sets when the SJB detects a short to ground from the LH trailer stop/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 trailer stop/turn lamp voltage supply. A trailer equipped with too many LH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8823 PINPOINT TEST Z: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - LH STOP/TURN LAMP NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- Z1 CHECK THE RECORDED DTCs FROM THE SJB SELF-TEST - Check the recorded results from the SJB self-test. - Was DTC B2070 present? Yes GO to Z2. No GO to Z6. ------------------------------------------------- Z2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND SELF-TEST WITH THE TRAILER DISCONNECTED - Disconnect the trailer from the vehicle. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Yes For the 4-pin connector, GO to Z5. For the 7-pin connector, GO to Z4. No GO to Z3. ------------------------------------------------- Z3 CHECK THE NUMBER OF BULBS ON THE TRAILER - Inspect the trailer for more than 2 LH stop/turn lamp bulbs. - Are more than 2 LH stop/turn lamp bulbs present? Yes INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for the trailer tow lamps to operate correctly. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- Z4 CHECK THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C473. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8824 GO to Z5. No INSTALL a new trailer tow connector. TEST the system for normal operation. ------------------------------------------------- Z5 CHECK CIRCUIT CAT06 (YE) FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to Z9. No REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. ------------------------------------------------- Z6 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Disconnect the trailer from the vehicle. - Ignition OFF. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C439-2, circuit CAT06 (YE), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow connector pin 1, circuit CAT06 (YE), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. TEST the system for normal operation. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8825 For the 4-pin connector, GO to Z8. For the 7-pin connector, GO to Z7. ------------------------------------------------- Z7 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C473. - While applying the brake pedal, measure the voltage between the trailer tow C473-1, circuit CAT06 (YE), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to Z8. ------------------------------------------------- Z8 CHECK CIRCUIT CAT06 (YE) FOR AN OPEN - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-14, circuit CAT06 (YE), harness side and the trailer tow C439-2 (4-pin) or C473-1 (7-pin), circuit CAT06 (YE), harness side. - Is the resistance less than 5 ohms? Yes GO to Z9. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- Z9 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8826 INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp Trailer Lamps Pinpoint Tests Pinpoint Test AA: The Individual Trailer Lamp Is Inoperative - RH Stop/Turn Lamp Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation Voltage to the RH trailer stop/turn lamp is supplied by the Smart Junction Box (SJB) through circuit CAT09 (GN). - DTC B2070 (Trailer Tow Relay Coil(s) Circuit Failure) - a continuous DTC that sets when the SJB detects a short to ground from the RH trailer stop/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 trailer stop/turn lamp voltage supply. A trailer equipped with too many RH stop/turn bulbs may also set the DTC. This pinpoint test is intended to diagnose the following: - Trailer equipped with too many bulbs - Wiring, terminals or connectors - Trailer tow connector - Trailer - SJB PINPOINT TEST AA: THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE - RH STOP/TURN LAMP NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- AA1 CHECK THE RECORDED DTCs FROM THE SJB SELF-TEST - Check the recorded results from the SJB self-test. - Was DTC B2070 present? Yes GO to AA2. No GO to AA6. ------------------------------------------------- AA2 CLEAR THE DTCs AND REPEAT THE ON-DEMAND SELF-TEST WITH THE TRAILER DISCONNECTED - Disconnect the trailer from the vehicle. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8827 Yes For the 4-pin connector, GO to AA5. For the 7-pin connector, GO to AA4. No GO to AA3. ------------------------------------------------- AA3 CHECK THE NUMBER OF BULBS ON THE TRAILER - Inspect the trailer for more than 2 RH stop/turn lamp bulbs. - Are more than 2 RH stop/turn lamp bulbs present? Yes INFORM the customer that the vehicle can only support 2 stop/turn lamp bulbs per side. Any additional stop/turn lamp bulbs need to be removed from the trailer or an adapter kit installed for the trailer tow lamps to operate correctly. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AA4 CHECK THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow 473. - Enter the following diagnostic mode on the scan tool: SJB Self-Test. - Clear the continuous DTCs. Repeat the on-demand self-test. - Is DTC B2070 still present? Yes GO to AA5. No INSTALL a new trailer tow connector. TEST the system for normal operation. ------------------------------------------------- AA5 CHECK CIRCUIT CAT09 (GN) FOR A SHORT TO GROUND - Ignition OFF. - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and ground. - Is the resistance greater than 10,000 ohms? Yes GO to AA9. No Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8828 REPAIR the circuit. RUN the on-demand self-test (required to clear certain DTCs). CORRECT any unresolved DTCs. CLEAR all DTCs. TEST the system for normal operation. ------------------------------------------------- AA6 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - For the 4-pin connector, while applying the brake pedal, measure the voltage between the trailer tow C439-1, circuit CAT09 (GN), harness side and ground. - For the 7-pin connector, while applying the brake pedal, measure the voltage between the trailer tow connector pin 4, circuit CAT09 (GN), component side and ground. - Is the voltage greater than 10 volts? Yes The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. TEST the system for normal operation. No For the 4-pin connector, GO to AA8. For the 7-pin connector, GO to AA7. ------------------------------------------------- AA7 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (7-PIN) - Disconnect: Trailer Tow C473. - While applying the brake pedal, measure the voltage between the trailer tow C473-4, circuit CAT09 (GN), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to AA8. ------------------------------------------------- AA8 CHECK CIRCUIT CAT09 (GN) FOR AN OPEN Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8829 - Disconnect: SJB C2280a. - Measure the resistance between the SJB C2280a-26, circuit CAT09 (GN), harness side and the trailer tow C439-1 (4-pin) or C473-4 (7-pin), circuit CAT09 (GN), harness side. - Is the resistance less than 5 ohms? Yes GO to AA9. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- AA9 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. TEST the system for normal operation. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test. ------------------------------------------------Pinpoint Test AB: The Trailer Lamps Are On Continuously Trailer Lamps Pinpoint Tests Pinpoint Test AB: The Trailer Lamps Are On Continuously Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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. The trailer tow parking lamps share the same voltage supply with the vehicle parking lamps. This pinpoint test is intended to diagnose the following: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8830 - Wiring, terminals or connectors - Trailer - SJB PINPOINT TEST AB: THE TRAILER LAMPS ARE ON CONTINUOUSLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. ------------------------------------------------- AB1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect the trailer from the vehicle. - Ignition ON. - Measure the voltage between the trailer tow connector, harness side and ground as follows: - Is any voltage present? Yes GO to AB2. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AB2 CHECK THE SJB - Ignition OFF. - Disconnect: SJB C2280a. - Ignition ON. - Measure the voltage between the trailer tow connector, harness side and ground as follows: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8831 - Is any voltage present? Yes REPAIR the circuit in question. TEST the system for normal operation. No GO to AB3. ------------------------------------------------- AB3 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AC: The Trailer Battery Charging Is Inoperative/Does Not Operate Correctly Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number 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 switch 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). This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - Trailer battery charge relay - Trailer tow connector - Trailer - SJB Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8832 PINPOINT TEST AC: THE TRAILER BATTERY CHARGING IS INOPERATIVE/DOES NOT OPERATE CORRECTLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- AC1 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTION (BATTERY CHARGE INOPERATIVE) - Ignition OFF. - Disconnect the trailer from the vehicle. - Ignition ON. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. Is the voltage greater than 10 volts? Yes GO to AC8. No VERIFY the BJB fuse 13 (30A) is OK. If OK, GO to AC2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AC2 CHECK THE TRAILER BATTERY CHARGE RELAY (INOPERATIVE) - Ignition OFF. - Disconnect: Trailer Battery Charge Relay. - Substitute the trailer battery charge relay with a known good relay. - Ignition ON. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. - Is the voltage greater than 10 volts? Yes REMOVE the known good relay. INSTALL a new trailer battery charge relay. TEST the system for normal operation. No REMOVE the known good relay. INSTALL the original relay. GO to AC3. ------------------------------------------------- Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8833 AC3 CHECK THE TRAILER TOW CONNECTOR - Ignition OFF. - Disconnect: Trailer Tow C473. - Ignition ON. - Measure the voltage between the trailer tow C473-5, circuit CAT14 (OG) and ground. Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to AC4. ------------------------------------------------- AC4 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY COIL - Ignition OFF. - Disconnect: Trailer Battery Charge Relay. - Ignition ON. - Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB face side and ground. - Is the voltage greater than 10 volts? Yes GO to AC6. No VERIFY the SJB fuse 12 (5A) is OK. If OK, GO to AC5. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. ------------------------------------------------- AC5 CHECK CIRCUIT CBP12 (GN/WH) FOR AN OPEN - Ignition OFF. - Disconnect: SJB C2280e. - Measure the resistance between trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB face side and the SJB C2280e-6, circuit CBP12 (GN/WH), harness side. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8834 - Is the resistance less than 5 ohms? Yes GO to AC12. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- AC6 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN - Ignition OFF. - Disconnect: Negative Battery Cable. - Measure the resistance between the trailer battery charge relay pin 85, circuit GD120 (BK/GN), BJB face side and ground. - Is the resistance less than 5 ohms? Yes GO to AC7. No REPAIR the circuit. TEST the system for normal operation. ------------------------------------------------- AC7 CHECK FOR VOLTAGE TO THE TRAILER BATTERY CHARGE RELAY - Measure the voltage between the trailer battery charge relay pin 30, circuit SSB13 (GY/RD), BJB face side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8835 - Is the voltage greater than 10 volts? Yes REPAIR circuit CAT14 (OG) for an open. TEST the system for normal operation. No REPAIR circuit SSB13 (GY/RD) for an open. TEST the system for normal operation. ------------------------------------------------- AC8 CHECK FOR VOLTAGE AT THE TRAILER TOW CONNECTOR (BATTERY CHARGE ALWAYS ON) - Ignition OFF. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. - Is any voltage present? Yes GO to AC9. No The vehicle is operating correctly. SEND the trailer to an authorized camper/trailer repair facility. ------------------------------------------------- AC9 CHECK CIRCUIT CAT14 (OG) FOR A SHORT TO VOLTAGE - Disconnect: Trailer Battery Charge Relay. - Measure the voltage between the trailer tow connector pin 5, circuit CAT14 (OG), component side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8836 - Is any voltage present? Yes REPAIR the circuit. TEST the system for normal operation. No GO to AC10. ------------------------------------------------- AC10 CHECK THE TRAILER BATTERY CHARGE RELAY (ALWAYS ON) - Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), BJB face side and ground. - Is any voltage present? Yes GO to AC11. No INSTALL a new trailer battery charge relay. TEST the system for normal operation. ------------------------------------------------- AC11 CHECK CIRCUIT CBP12 (GN/WH) FOR A SHORT TO VOLTAGE - Disconnect: SJB C2280e. - Measure the voltage between the trailer battery charge relay pin 86, circuit CBP12 (GN/WH), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8837 Is any voltage present? Yes REPAIR the circuit. TEST the system for normal operation. No GO to AC12. ------------------------------------------------- AC12 CHECK FOR CORRECT SJB OPERATION - Disconnect all the SJB connectors. - Check for: corrosion - damaged pins - pushed-out pins - Connect all the SJB connectors and make sure they seat correctly. - Operate the system and verify the concern is still present. - Is the concern still present? Yes INSTALL a new SJB. CLEAR any DTCs. REPEAT the self-test. No The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. ------------------------------------------------Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Trailer Lamps Pinpoint Tests Pinpoint Test AD: The Trailer Electric Brakes Are Inoperative/Do Not Operate Correctly Refer to Wiring Diagram Set 95, Trailer/Camper Adapter for schematic and connector information. See: Diagrams/Electrical Diagrams/Diagrams By Number Normal Operation The is provided voltage at all times by the Battery Junction Box (BJB) fuse 17 (30A) through circuit SBB17 (RD). Ground for the TBC module is provided through circuit GD138 (BK/WH). The TBC module receives voltage from the stoplamp switch through circuit CCB08 (VT/WH) when the brake pedal is applied. When requested, the TBC module provides voltage to the trailer tow connector through circuit CAT19 (BU). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8838 This pinpoint test is intended to diagnose the following: - Fuse - Wiring, terminals or connectors - TBC module - Trailer tow connector - Trailer PINPOINT TEST AD: THE TRAILER ELECTRIC BRAKES ARE INOPERATIVE/DO NOT OPERATE CORRECTLY NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct probe adapter(s) may damage the connector. NOTE: Before beginning diagnostics, visually inspect the trailer tow connector for signs of corrosion or damage. Repair or install a new trailer tow connector as required. NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to Battery. ------------------------------------------------- AD1 CHECK FOR VOLTAGE TO THE TRAILER TOW CONNECTOR (INOPERATIVE CONDITION) - Ignition OFF. - Disconnect the trailer from the vehicle. - While applying the brake pedal, measure the voltage between the trailer tow connector pin 3, circuit CAT19 (BU), component side and ground. - Is the voltage greater than 10 volts? Yes GO to AD8. No GO to AD2. ------------------------------------------------- AD2 CHECK THE TRAILER TOW CONNECTOR - Disconnect: Trailer Tow C473. - While applying the brake pedal, measure the voltage between the trailer tow C473-3, circuit CAT19 (BU), harness side and ground. - Is the voltage greater than 10 volts? Yes INSTALL a new trailer tow connector. TEST the system for normal operation. No GO to AD3. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8839 ------------------------------------------------- AD3 CHECK CIRCUIT SBB17 (RD) FOR AN OPEN - Disconnect: C238. - Measure the voltage between the TBC module C238-1, circuit SBB17 (RD), harness side and ground. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8840 ERROR: undefined OFFENDING COMMAND: ‘~ STACK: Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8844 Trailer Lighting Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8845 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8851 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8852 Turn Signal Lamp: Diagrams Park/Turn Lamp, Left Front Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8853 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8854 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8855 Turn Signal Lamp: Diagrams Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8856 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8857 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8858 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8859 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8860 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8861 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8862 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8863 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8864 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8865 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Turn Lamp, Left Rear > Page 8866 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8870 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8871 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8872 Turn Signal Switch: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8873 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8874 Turn Signal Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Vanity Mirror Lamp, Left > Page 8879 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8885 Heated Glass Element Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8886 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8891 Heated Glass Element Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 8892 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 8898 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 8899 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 8900 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8903 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8904 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8905 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8906 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8909 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8910 Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and Rear Doors Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 8911 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 8912 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 (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Service and Repair Back Window Motor: Service and Repair Window Regulator Motor - Rear Removal and Installation NOTE: The power rear window motor must be initialized when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window glass module is installed, and any operation in which grease or lubricants are applied to the power rear window system. 1. Remove the rear window glass regulator. For additional information, refer to Window Regulator Rear See: Window Regulator/Back Window Regulator/Service and Repair. 2. Remove the 3 window regulator motor bolts. - To install, tighten to 4 Nm (35 lb-in). 3. Remove the window regulator motor. 4. To install, reverse the removal procedure. - Initialize the power rear window motor. For additional information, refer to Window Motor Initialization - Rear See: Service and Repair/Window Motor Initialization - Rear. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8922 Front Door Window Motor: Service and Repair Window Regulator Motor - Front Door Window Regulator Motor - Front Door Removal and Installation NOTE: For LH front only, the front window motor must be initialized whenever the front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run. 1. Remove the front door window regulator. For additional information, refer to Window Regulator Front Door See: Window Regulator/Front Door Window Regulator/Service and Repair/Window Regulator - Front Door. 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. - For LH front window only, initialize the LH front window motor. For additional information, refer to Window Motor Initialization - Front See: Service and Repair/Window Motor Initialization - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door Rear Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door NOTE: Explorer shown, Explorer Sport Trac similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 8927 Rear Door Window Motor: Service and Repair Window Regulator Motor - Rear Door Window Regulator Motor - Rear Door 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 (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 8932 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 8933 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Master Window Adjust Switch > Page 8934 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch Power Window Switch: Diagrams Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8937 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8938 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8939 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Master Window Adjust Switch > Page 8940 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch Power Window Switch: Testing and Inspection Master Window Adjust Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 8943 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 8944 Power Window Switch: Testing and Inspection Window Adjust Switches - Passenger Side and Rear Doors Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Master Window Adjust Switch > Page 8945 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 8946 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 (V6-4.0L (2009)) 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 Removal NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the existing rear window glass. 1. Remove the cab rear panel. 2. Remove the 15 rear window glass mounting nuts. 3. NOTICE: Use only a plastic windshield setting tool to slide under the seal to separate the foam core butyl from the glass. Once the glass starts to separate from the body, constant hand pressure will break the seal and the glass can be removed. Failure to use a plastic windshield setting tool can damage the body or the glass frame. Remove the rear window glass. Installation 1. NOTE: Remove as much as possible of the foam core butyl from the body and rear window glass prior to installation. Install the rear window glass. - Apply foam core butyl to the window. Overlap the foam core butyl by 25 mm (0.984 in) at the bottom middle of the rear window glass. - Carefully install the rear window glass into the body opening. 2. Install the 15 rear window glass mounting nuts. - Tighten to 3 Nm (27 lb-in). - Test the rear window glass for water leaks. 3. Install the cab rear panel. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 8952 Back Window Glass: Service and Repair Window Glass - Rear, Power Window Glass - Rear, Power Removal NOTE: The power rear window motor must be initialized when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window glass module is installed, and any operation in which grease or lubricants are applied to the power rear window system. NOTE: If the rear window glass is being removed to repair a dust/water leak, remove and reinstall the existing rear window glass. 1. Remove the rear window glass regulator. For additional information, refer to Window Regulator Rear See: Window Regulator/Back Window Regulator/Service and Repair. 2. Remove both C-pillar upper trim panels. 3. Remove the 12 rear window glass mounting nuts. 4. NOTICE: Use only a plastic windshield setting tool to slide under the seal to separate the foam core butyl from the glass. Once the glass starts to separate from the body, constant hand pressure will break the seal and the glass can be removed. Failure to use a plastic windshield setting tool can damage the body or the glass frame. Remove the rear window glass. Installation 1. NOTE: Remove as much as possible of the foam core butyl from the body and rear window glass prior to installation. Install the rear window glass. - Apply foam core butyl to the window. Overlap the foam core butyl by 25 mm (0.984 in) at the bottom middle of the rear window glass. - Carefully install the rear window glass into the body opening. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Window Glass - Rear, Fixed > Page 8953 2. Install the 12 rear window glass mounting nuts. - Tighten to 3 Nm (27 lb-in). - Test the rear window glass for water leaks. 3. Install both C-pillar upper trim panels. 4. Install the rear window glass regulator. For additional information, refer to Window Regulator Rear See: Window Regulator/Back Window Regulator/Service and Repair. Initialize the power rear window motor. For additional information, refer to Window Motor Initialization - Rear See: Service and Repair/Window Motor Initialization - Rear. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8959 Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front Door Glass Top Run - Front Removal and Installation NOTE: For LH front only, the front window motor must be initialized whenever the front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run. 1. Remove the front door window glass. For additional information, refer to Window Glass - Front Door See: Service and Repair/Window Glass Front Door. 2. Remove the exterior moulding. 3. Remove the front door glass top run channel assembly bolt. - To install, tighten to 12 Nm (106 lb-in). 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. - For LH front window only, initialize the LH front window motor. For additional information, refer to Window Motor Initialization - Front See: Service and Repair/Window Motor Initialization - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 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. NOTE: Open and support the liftgate window glass before removing the liftgate window glass struts. 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 (V6-4.0L (2009)) 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 NOTE: LH shown, RH similar. Removal 1. Remove the rear quarter trim panel. 2. Remove the wiring harness brackets. 3. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area. - Use a clean shop towel or oil-free compressed air. 4. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8966 WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal. NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement glass. NOTE: Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive. 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. NOTE: Support the glass to prevent the glass from dropping while cutting the urethane adhesive. Using the Deluxe Windshield Removal Tool, cut the urethane adhesive from the quarter window glass starting at the upper center of the quarter window glass and working toward the bottom corners. 5. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive and carefully remove the quarter glass from the vehicle and place on a stable work surface. Installation 1. Dry fit the rear quarter window glass in the window opening. - Position the quarter window glass on the pinch weld. - Center the quarter glass in the opening for best fit. - Make alignment marks with tape or non-staining grease pencil on the quarter window glass and the body. 2. After the dry-fit alignment, remove the glass from the opening and place on a stable work surface with the interior side of the glass facing upward. 3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s). NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and urethane adhesive. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinch weld. 4. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during glass removal. 5. If reinstalling the original quarter window glass, remove the excess urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive bead. 6. Clean the inside of the new quarter window glass with glass cleaner. - Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied. 7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this procedure. If installing a new rear quarter window glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Page 8967 8. Cut the urethane adhesive applicator tip to specification. 9. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and continuous bead. NOTE: The rear quarter glass must be positioned within 10 minutes of applying the urethane adhesive. 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. - Make sure there are no gaps in the urethane bead. 10. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s). NOTICE: Before positioning the quarter window glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond. Using the alignment marks made previously, position the quarter window glass on the pinch weld. 11. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. 12. Install the wiring harness brackets. 13. Install the rear quarter trim panel. 14. Clean the exterior and interior of the quarter window glass with glass cleaner. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear Rear Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Rear Door Glass Top Run - Rear Removal and Installation 1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear Door See: Service and Repair/Window Glass Rear Door. 2. Remove the exterior moulding. 3. Remove the rear door glass top run assembly bolt. - To install, tighten to 12 Nm (106 lb-in). 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 (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Glass Top Run - Rear > Page 8973 Rear Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door NOTE: Explorer shown, Explorer Sport Trac similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair Back Window Regulator: Service and Repair Window Regulator - Rear Removal and Installation NOTE: The power rear window motor must be initialized when repairs are performed on any part of the power rear window system including when: the power rear window motor is removed from the window regulator drum housing, a new power rear motor is installed, a new power rear window regulator is installed, a new power rear window glass module is installed, and any operation in which grease or lubricants are applied to the power rear window system. 1. Remove the cab rear panel. 2. Position the insulator aside. 3. Remove the 8 window regulator cover bolts. - To install, tighten to 10 Nm (89 lb-in). 4. Remove the window regulator cover-to-motor bolt. - To install, tighten to 10 Nm (89 lb-in). 5. Remove the window regulator cover. 6. Remove the 2 window regulator mounting nuts. - To install, tighten to 10 Nm (89 lb-in). 7. Remove the 2 window regulator-to-window bolts. - To install, tighten to 11 Nm (97 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Page 8978 8. Disconnect the electrical connector. 9. Remove the window regulator. 10. To install, reverse the removal procedure. - Initialize the power rear window motor. For additional information, refer to Window Motor Initialization - Rear See: Service and Repair/Window Motor Initialization - Rear. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Front Door Glass, Frames and Mechanisms - Exploded View, Front Door NOTE: LH shown, RH similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 8983 Front Door Window Regulator: Service and Repair Window Regulator - Front Door Window Regulator - Front Door Removal and Installation NOTE: For LH front only, the front window motor must be initialized whenever the front window motor is removed from the window regulator drum housing, a new window regulator is installed, a new top run is installed or for any operation in which grease or lubricants are applied to the window regulator or glass run. 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. NOTICE: Make sure the holes in the glass bracket do not become enlarged during the rivet removal process. Damage to the window regulator will occur 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. 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. - For LH front window only, initialize the LH front window motor. For additional information, refer to Window Motor Initialization - Front See: Service and Repair/Window Motor Initialization - Front. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door Rear Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded View, Rear Door Glass, Frames and Mechanisms - Exploded View, Rear Door NOTE: Explorer shown, Explorer Sport Trac similar. 1. For additional information, refer to the procedures. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Rear Door > Page 8988 Rear Door Window Regulator: Service and Repair Window Regulator - Rear Door Window Regulator - Rear Door 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. NOTICE: Make sure the hole in the glass bracket does not become enlarged during the rivet removal process. Damage to the window regulator will occur 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 rear window regulator mounting 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 (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass Windshield: Service and Repair Windshield Glass Windshield Glass Removal 1. Remove the RH and LH side A-pillar trim panels. 2. Remove the sun visors and retainers and, if equipped, the overhead console. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8993 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 cowl panel grille. 7. 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. 8. NOTE: LH shown, RH similar. Lower the setting blocks. - Use a flat screwdriver to release the setting block and lower. 9. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield pinch weld area. - Use a clean shop towel or oil-free compressed air. 10. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury. WARNING: Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in serious personal injury. NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise damage the pinch weld during glass removal. NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the replacement windshield glass. NOTE: Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting the urethane adhesive. NOTE: Support the windshield glass to prevent the glass from dropping while cutting the urethane adhesive. Using the Deluxe Windshield Removal Tool, cut the urethane adhesive from the windshield glass starting at the upper center of the windshield glass and working toward the bottom corners. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8994 11. Using The Pumper, distance the windshield from the body. 12. Using the Deluxe Windshield Removal Tool, cut the remaining urethane adhesive. 13. NOTE: Removing the windshield glass requires more than one technician. NOTE: If reinstalling the windshield glass, tape the windshield at the windshield stops to aid in alignment of the glass during installation. Carefully remove the windshield glass from the vehicle and place on a stable work surface. 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 new windshield glass on the existing urethane adhesive bead on the pinch weld. - Position the windshield glass on the pinch weld. - Center the windshield glass in the opening. - Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass setting blocks) on the windshield glass and the body. 3. After the dry-fit alignment, remove the glass assembly from the windshield opening and place on a stable work surface with the interior side of the glass facing upward. 4. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s). NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch weld following manufacturer's instructions. Use the same brand pinchweld primer, glass primer and urethane adhesive. Using an appropriate tool, trim the urethane adhesive leaving a 1 mm to 2 mm (0.04 in to 0.08 in) base of original equipment urethane adhesive on the pinch weld. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8995 5. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the existing urethane adhesive. Remove any foreign material or water that may have entered during windshield removal. 6. If installing the original windshield glass, remove the excess urethane adhesive from the glass leaving a thin layer to bond with the new urethane adhesive 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. Clean the inside of the new windshield glass with glass cleaner. - Make sure to thoroughly clean the surface of the blackened border area where the urethane adhesive will be applied. 8. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material Chart in this procedure. If installing a new windshield glass, apply glass primer according to manufacturer's instructions. Allow at least 6 minutes to dry. 9. Cut the urethane adhesive applicator tip to specification. 10. NOTE: Use either a high-ratio, electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and continuous bead. NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane adhesive. Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and ending at the bottom of the windshield near the center, making sure there are no gaps in the bead. 11. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions may result in serious injury to vehicle occupant(s). NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure of closing doors from affecting the urethane adhesive bond. Using the alignment marks made previously, position the windshield glass on the pinch weld. 12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air and water leaks. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8996 13. NOTE: Follow the same routing for the electrical connector that was used during removal. If equipped, connect the heated windshield electrical connectors. 14. Install the cowl panel grille. 15. Raise the front portion of the headliner. 16. Install the interior mirror. 17. Install the sun visors, retainers and, if equipped, the overhead console. 18. If equipped, install the roof opening panel trim. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8997 Windshield: Service and Repair Glass Reseal - Windshield Glass Reseal - Windshield 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 cowl panel grille. 7. Clean the edge formed by the existing urethane adhesive and the glass on the inside at the top, sides and outside on the bottom of the windshield with glass cleaner. 8. Cut the urethane adhesive applicator tip to specification. 9. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane adhesive with less effort and a continuous bead. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead. Apply a bead of urethane adhesive over the top of the existing urethane adhesive. - Apply the urethane adhesive to the top and sides of the windshield glass from the interior of the vehicle. - Apply the urethane adhesive to the bottom of the windshield glass from the exterior of the vehicle. 10. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water leaks. After the urethane adhesive has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 11. Install the cowl panel grille. 12. Raise the front portion of the headliner. 13. Install the interior mirror. 14. Install the sun visors, retainers and, if equipped, the overhead console. 15. If equipped, install the roof opening panel trim. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield Glass > Page 8998 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 (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 9004 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9008 Wiper Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9009 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9014 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9015 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9019 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9020 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Windshield Washer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 9023 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 9024 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 9025 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 9026 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9030 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9031 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch Wiper Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9034 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9035 Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9036 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 9037 Wiper Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9041 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9042 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor Windshield Washer Motor: Locations Two-Way Washer Pump Motor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor > Page 9047 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor > Page 9048 Windshield Washer Motor: Locations Washer Pump Motor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Two-Way Washer Pump Motor > Page 9049 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Washer Pump Motor Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Washer Pump Motor > Page 9052 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the windshield washer pump electrical connector. 3. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before washer pump removal. Disconnect the windshield washer reservoir hoses. 4. NOTE: When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. Remove the windshield washer pump. 5. NOTICE: Do not operate the windshield washer pump before filling the windshield washer reservoir. Failure to do so could result in premature pump failure. To install, reverse the removal procedure. - Fill the windshield washer reservoir with windshield washer fluid. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the Air Cleaner (ACL) assembly. 3. Remove the RH front fender splash shield. 4. Disconnect the windshield washer pump electrical connector. 5. Disconnect the windshield washer solvent level electrical connector. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. NOTE: If necessary, drain the windshield washer reservoir after removal. 6. Disconnect the windshield washer reservoir hoses. 7. Remove the top bolt. - To install, tighten to 5 Nm (44 lb-in). Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 9059 8. Remove the side bolt. - To install, tighten to 5 Nm (44 lb-in). 9. Remove the bolt. - To install, tighten to 5 Nm (44 lb-in). 10. Remove the windshield washer pump reservoir. 11. NOTICE: When servicing the windshield washer pump, be careful not to damage the windshield washer pump seal. Transfer components as necessary. 12. NOTICE: Do not operate the washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9063 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 9064 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch Windshield Washer Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9067 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9068 Windshield Washer Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9069 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 9070 Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch NOTE: Steering wheel removed for clarity. Removal and Installation NOTICE: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the 2 screws and the steering column opening cover. 2. Remove the 3 screws and the upper and lower steering column shrouds. 3. Disconnect the multifunction switch electrical connector. 4. Remove the 2 multifunction switch screws and the multifunction switch. - To install, tighten to 3 Nm (27 lb-in). 5. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 that the RH and LH wiper blades are located at the specified position. 3. NOTE: Make sure there is no mechanical binding in the linkage preventing the wiper arms from returning to the fully parked position. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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. For additional information, refer to Wiper Blade and Pivot Arm Adjustment - Windshield See: Adjustments. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9076 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 (150 lb-in). 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. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Pivot Arm - Front > Page 9077 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 (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 9081 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 9085 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 9086 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) 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 NOTE: A new wiper motor assembly comes with the linkage arm installed. 1. Remove the front wiper pivot arms. For additional information, refer to Wiper Pivot Arm - Front See: Wiper Arm/Service and Repair/Wiper Pivot Arm - Front. 2. NOTICE: To avoid breaking the retaining clips on the cowl panel, do not pull up on the rear of the cowl panel. Pry up on the front of the cowl panels to release it from the retaining clips. 3. Remove the cowl panel grilles. 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 (133 lb-in). 6. Remove the windshield wiper assembly and position on a workbench. 7. NOTICE: Do not remove the wiper motor linkage arm from the wiper motor assembly. If the arm is removed, the wiper arms may not park in the correct location. Separate the wiper motor linkage arm from the wiper mounting arm and pivot shaft assembly. - Use a suitable tool at the location shown to separate the wiper linkage arm from the wiper mounting arm and pivot shaft assembly. 8. Remove the 3 windshield wiper motor mounting bolts. - To install, tighten to 15 Nm (133 lb-in). 9. Remove the windshield wiper motor. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 9089 10. NOTE: The windshield wiper motor must be cycled to make sure it is in the park position before installing the wiper pivot arms. To install, reverse the removal procedure. Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Windshield > Page 9090 Wiper Motor: Service and Repair Wiper Motor - Rear Window Wiper Motor - Rear Window Removal and Installation 1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear See: Wiper Arm/Service and Repair/Wiper Pivot Arm - Rear. 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 (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9094 Wiper Relay: Testing and Inspection Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9095 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9099 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 9100 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch Wiper Switch: Testing and Inspection Multifunction Switch Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9103 Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9104 Wiper Switch: Testing and Inspection Multifunction Switch, Wiper/Washer Portion Ford Explorer Sport Trac 4wd Workshop Manual (V6-4.0L (2009)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Multifunction Switch > Page 9105